Investigation of factors influencing the quality of surfaces produced by ISMF process

Dissertant

Ubayd, Nareen Hafiz

Thesis advisor

Saraji, Wisam Kazim Hamdan
Muhammad, Jamal H.

University

University of Technology

Faculty

-

Department

Department of Production Engineering and Metallurgy

University Country

Iraq

Degree

Master

Degree Date

2012

English Abstract

Incremental Sheet Metal Forming (ISMF) is a novel sheet metal forming technology where the deformation of the thin sheet metal blank occurs locally and progressively by using the CNC milling machine which control the movement of a simple forming tool.

The surface quality is of vital importance in any manufacturing process.

Therefore, the present study is focused on the surface quality of parts formed by single point incremental forming (SPIF) process.

Consequently, the objective of this study is to investigate the effect of five forming parameters (number of forming stages, feed rate type, tool overlapping, rotational speed, and state of initial blank) on the dimensional accuracy and surface roughness of parts.

Each control factor is studied based on two levels (low level and high level).

To study the effects of these control factors, a D-optimal Design of Experiment is used to develop the experimental plan and analyze data.

Experimental tests were carried out on sheets of aluminum with thickness 1.1 mm.

Multiple regressions are used for building the types of response surface model in five variables via interaction terms to predict the surface roughness and geometrical deviation in advance and for any value of process parameters lower than (-1) or upper than (1) level which are not experimentally studied.

Both quantitative and qualitative assessments have been used to explore the effects of the five forming factors on the surface quality of parts formed by SPIF process.

The ANOVA results show that the tool overlapping and the number of forming stages are the most important factors affecting the surface roughness.

These two factors are proportional to the surface roughness.

The maximum and minimum surface roughness, which is achieved from all the 16 experiments is (Ra = 4.06 & Ra = 2.04 μm) respectively.

On the other hand, the number of forming stages and the state of initial blank are the most influential factors affecting the geometrical deviation.

These two factors are inversely proportional to the geometrical deviation.

The maximum and minimum experimental geometrical variations gathered are (δ = 4.41 and δ = 0.76 mm).

The qualitative assessment reveals that the surface roughness decreases radialy as the tool moves towards the center of the blank.

Main Subjects

Engineering & Technology Sciences (Multidisciplinary)

• APA
• MLA
• AMA

Language

English

Data Type

Arab Theses

Record ID

BIM-419534