Investigation of the effects of experimental parameters on the processing of AA5754-H22 alloy by SPIF method

Abstract

Single point incremental forming (SPIF), which is a method that can be controlled by CNC processes without the need for a mold, as in traditional sheet metal forming, reduces costs and is suitable for low production series. In this study, the thickness change, surface roughness, and spring-back behaviours of AA5754-H22 alloy, which is widely used in many industries, especially in aviation and automotive, after forming with the SPIF method, were experimentally investigated. The geometric shape used in the study is hexagonal. The study was carried out using the parameters of increment (0.25, 0.5 mm), feed rate (500, 1000 mm/min), spindle speed (1000, 1500 rpm), tool diameter (6, 10 mm), wall angle (50, 55°), lubricant (machine oil, sunflower oil). The results were analysed after the experiments were conducted using an L16 orthogonal experimental design with the Taguchi method, and variance analysis was performed. As a result of the experiments, it was determined that the most important parameter affecting the wall thickness was the wall angle with a rate of 95.33%, the most important parameter affecting the surface quality was the tool diameter with a rate of 70% and the most important parameter affecting the spring-back was the wall angle with a rate of 52.76%. From here, it was understood that the parameters affecting the spring-back were in a wider range. In addition, when all the results were taken into consideration, it could be said that the most effective parameter was the wall angle.