Experimental investigation and finite element modeling on profile forming of conical component using Al 3003(O) alloy

Profile forming of sheet metal is a special technique that offers flexibility and cost-effectiveness in the metal forming process, requiring no high capacity presses or set of dies, thus meeting the ever increasing demand for small batch production and rapid prototyping. This paper demonstrates the formation of sheet metal part using the CNC controlled hemispherical tool and analyses the various parameters underlying this mechanism – like maximum wall angle, surface roughness (Ra) and thinning of sheet. Analysis of the microstructure is carried out using Scanning electron microscopy and Energy-dispersive X-ray spectroscopy microanalysis test. In this study, Aluminum sheet of grade Al 3003(O) with 1 mm and 1.25 mm thickness is used as a work piece. The paper also presents an explicit numerical simulation using the standard finite element code ABAQUS and the experimental and numerical results are validated.

► As the forming angle decreases, a thinner sheet experiences a larger springback.
► The Surface finish is good for a larger radius of forming, when compared to a smaller radius.
► The lesser the thickness of the sheet, the better the surface finish. A large increment step size, gives a higher roughness.