Residual stress measurement of single point incremental formed Al/Cu bimetal using incremental hole-drilling method

Residual stress (RS) is an important parameter which affect performance and dimensional stability of components. In the manufacturing process, RS mostly was produced by mechanical and thermal causes. In the present work, concept of residual stress is introduced in the area of single point incremental forming (SPIF) of Al/Cu bimetal. The chosen profile for single point incremental forming is parabolic shape where provide angular and linear displacement. In this regard, influence of process parameters such as tool diameter, step down, and rotational speed are investigated on the residual stress using incremental hole-drilling method. Since there was not any standard for calculation of calibration coefficients in the multilayers, so finite element approach was considered to find the calibration coefficients. Results showed that the tool diameter of 16 mm and step down of 0.25 mm produces less RS and also rotational speed variation does not affect much on RS.