Application of a hybrid optimization technique in a multiple sheet single point incremental forming process

• Multiple sheet single point incremental forming process (MSSPIF) was conducted for the first time.
• The input process parameters were optimized by using a new hybrid optimization technique.
• ANOVA results show that the major contributing factor as feed rate.
• Residual plot analysis shows that the process parameters selected have significance.
• Confirmation test results show that there is an improvement in grey relational grade values.

Incremental forming of sheet metals is a reliable area where industry can focus in the future due to enormous opportunities available for automation. Due to the slow speed and low accuracy, the process has not yet been embraced by industry. Single point incremental forming with multiple sheets can improve the production rate considerably. In this paper, a hybrid optimization technique is used by combining Taguchi grey relational analysis (TGRA) and response surface methodology (RSM) to determine an optimal combination of input process parameters, such as the number of sheets, the tool diameter, the feed rate, the spindle speed and the vertical step depth, required to obtain favorable responses. Promising results were obtained from the optimization, and the results were validated using a confirmatory experiment demonstrating that the process could be effectively improved and that the optimization technique is robust.

Experimental results shows that a feed rate of 300 mm/min, vertical step depth of 1.3 mm, tool diameter of 11 mm, spindle speed of 300 rpm and number of sheets of 2 provide the optimum parametric condition during MSSPIF processing of commercially pure copper sheets by employing hybrid optimization using grey relational analysis and response surface methodology.Figure optionsDownload as PowerPoint slide