Investigating the Impact of Process Parameters on Thinning and Formability in Aluminum Alloy AA 1050 Incremental Sheet Metal Forming

To make cone-shaped structures with SPIF, the spindle speed (1000, 1500, and 2000 RPM), feed rate (200, 400, and 600 mm/min), tool width (8, 10, and 12 mm), and step-down (0.2, 0.4, and 0.6 mm) at the specimen interface were all changed. For aluminum alloy AA 5010, the maximum thinning (mm) and formability (%) were the important mechanical qualities. The L9 orthogonal array was used for a complete look at these qualities. Making high-quality cones using a computer numerically controlled machine was the aim of this research. (CNC) machine. The important factors affecting engineering and forming quality were studied using the Taguchi and analysis of variance methods. The most influential factor on maximum thinning was the rotational speed followed by the feeding, which is inversely proportional to it. In contrast, the most effective factor on the formability is the feeding followed by the rotational speed, which is directly proportional to it. It was discovered that a spindle speed of 1500 revolutions per minute (RPM), a feed rate of 200 millimeters per minute (mm/min), a tool diameter of 10 millimeters (mm), and a step down of 0.4 millimeters provide the least amount of maximum thinning (mm) and formability (percent).