Investigating the effect of input parameters on tool wear in incremental sheet metal forming

Abstract

Abstract Over the years incremental sheet metal forming (ISMF) has developed as a futuristic technique in which the metal sheets are transformed into the final product with the use of a solid metallic rod having a designed end, rather than a dedicated die. The production lead time is quite high in this process as compared to the conventional sheet forming methods. ISMF is most suitable for developing model for the purpose of research and development, manufacturing of the customized part and for low-volume production. Tool life is an important criterion for determining feasibility of any manufacturing process. The sliding of the forming tool over the clamped metal worksheet during the ISMF is another important aspect for understanding the tool-wearing behaviour. The present study has investigated the wearing of the 440C grade steel forming tool during the ISMF of aluminum grade AA3003-O. It has examined the process statistically to establish that the step downsize ( P = 0.021) and sheet metal thickness ( P = 0.005) significantly influence the wearing of 440C steel tool. The coefficient of performance, i.e., R 2 has been reported as 92.0 % with an adjusted R 2 of 81.9 %.