Influence of some Relevant Process Parameters on The Surface Roughness of Surfaces Produced by ISMF Proce

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