Professional Documents
Culture Documents
Bai Bao Nuoc Ngoai Sau TS 12
Bai Bao Nuoc Ngoai Sau TS 12
Abstract. The objective of this paper is to select a set of technological forming parameters including
vertical feed ∆z, feeding rate of vxy of the tool (a kind of pestle but no-cutting edges), the diameter of
tool D and the revolutions per minute of tool n to achieve the highest forming ability of stainless steel
sheet SUS304 (according to JIS Japanese standard) when forming metal sheet by Single Point
Incremental Forming Technology- SPIF. The content of the article consists of 3 processes:
− Pre-design of experiment (Pre-DOE) to select of a set of reasonable limited parameters when
forming SUS304 stainless steel models when forming on the existent specialist SPIF machine in
the National Key Laboratory of Digital Control and System Engineering laboratory
(DCSELAB);
− Performing SUS304 models on the Pre-DOE to obtain the forming angle values.
− Evaluating the experimental results by Analyzing of the variance.
− Setting up the regression equation of the angle of deformability with influence parameters
− Optimization the regression equation to select an optimal set of forming parameters to gain the
highest deformability of stainless-steel sheet SUS304.
All rights reserved. No part of contents of this paper may be reproduced or transmitted in any form or by any means without the written permission of Trans
Tech Publications Ltd, www.scientific.net. (#542582317-03/09/20,11:18:57)
60 Materials and Processing Technologies
Figure 1: Two categories of ISF: (a) SPIF and (b) TPIF [2].
In order to study the deformability of models, almost all researchers have always selected the
circular tapered shapes of the model as shown in Figure 2.
Figure 2: The circular tapered shapes of the model is suitable for measuring the deformability angle
α in experiment.
This model can help us to measure the angle α at any random depth z of the model because its
lateral profile is a curved cone shape because α is made by the tangent line of curved cone shape and
the horizontal line. There is a relationship between depth z and α. Because at the maximum depth z
R−z
where the model is torn, we could calculate the angle α according to the formula α = arccos
R
[2]. The deeper of depth z, the greater the formability α that could show us the gradual forming angle
of this technology and respond the purpose of the article. The forming angle α relates to the 4 above
parameters of SPIF technology.
2. Selection of method of Design of experience (DOE) and suitable regime of forming for SUS304
The selection and distribution of the values of the 4 forming parameters are based on the
capabilities of SPIF machine and the experimental plan of part with 2 boundary values [4]. With the
selected Partial DOE of 4 parameters, 2 limited values of each, the number of samples to be performed
is 24-1 = 8 samples. With the number of iterations is 3, the total of samples to be formed is 3x8 = 24
samples [5]. The regimes of forming of 1 iteration of experience are presented in the following table 3:
Table 3: Regimes of forming stainless steel SUS304
Vertical feed ∆z Diameter of tool D Feeding rate vxy Revolution of tool n
Run
[mm] [mm] [mm/min] [rpm]
1 0.2 5 800 400
2 0.2 5 3000 800
3 0.2 10 800 800
4 0.2 10 3000 400
5 1 5 800 800
6 1 5 3000 400
7 1 10 800 400
8 1 10 3000 800
Experimental Forming
With the iteration number of 3, total 24 samples of SUS304 stainless-steel are formed successively 3
times according to the selected modes in Table 3 on the SPIF specialized machine at DCSELAB. The
specialized SPIF machine, its feather and gauge instrument are shown in Figure 3.
62 Materials and Processing Technologies
Figure 3: Left: Specialist SPIF machine. Right: feather and accessories were used for experiments
in DCSELAB
Right: The torn formed model is measured to find the deepest value or the maximum deformable
angle
− The feather has been analyzed on stresses and displacements by Solidworks to define its stiffness
before experiment [6]. The displacement of the feather is so small that can be negligible so it can
be considered as a robust rigid technology frame system as shown in Figure 4.
Figure 4: The displacement of the feather is considered almost be zero by Solidworks, proving the
rigidity of the technology system before forming SUS 304 stainless steel models.
− Lubrication: Due to the huge heat generated when forming, it is necessary to use emulsion slurry of
5% soluble oil solution to lubricate and cool down heat of the tools and sheet materials (Figure 5).
Key Engineering Materials Vol. 863 63
Figure 5: Cooling and lubricating the pestle by emulsion slurry of 5% soluble oil solution.
− Experimental results for determining the average of forming angle of SUS304 with 3 iterations,
number of models to form is 3x8 = 24 (Table 4).
Table 4: Experimental results to get the mean deformable angles of SUS304 stainless steel sheet.
Run Vertical Feed Diameter of Feeding rate Revolution of Mean formable
∆z tool D vxy tool n angle
[mm] [mm] [mm/ min] [rpm] [oC]
1 1 5 800 800 65.36
2 0.2 5 800 400 66.41
3 1 10 800 400 62.44
4 0.2 10 800 800 63.68
5 1 5 3000 400 63.41
6 0.2 5 3000 800 66.27
7 1 10 3000 800 65.84
8 0.2 10 3000 400 64.15
Analysis the results of experiment of 3 set of deformable angle by analysis of variance (ANOVA)
Before establishing the regression equation of the deformable angle, it is necessary to analyze the
variance (Anova: Analysis of Variance) to see if the experimental results are truthful. Anova is used
when studying the truthfulness effect of experimental results of forming angle of SUS 304.
Anova results with a very small value of P-value = 6.68E-7 shows that the reliability of experimental
More specifically, we optimize the regression equation of the aforementioned forming angle α in
order to gain a specific set of 4 optimal forming parameters along with the maximum value of the
forming angle by Microsoft Excel / Solver, a popular software, as shown in the Figure 7:
However, when application the obtained optimal parameters to form 3 samples of the same
specific SUS304 sheet, the biggest average forming angle can only be achieved up to 51,79 degree.
This can be explained by the defection of material, uncontrolled random conditions in the experiment,
the vibration of the foundation of the workshop via other machines and the differences of ambient
and machine temperatures when forming.
Conclusions
After optimization of the regression equation of the deformable angle of stainless steel SUS304 to
achieve the optimal set of forming parameters, we can draw conclusions:
For stainless steel SUS304, it is necessary to select the minimum values of all the forming
parameters to get maximum angle of deformation. Therefore, the vertical feed ∆z after each cycle,
the tool diameter D, the speeding rate of tool vxy and the revolutions of tool or spindle n should be as
small as possible. Thus, the productivity of maximum ability of deforming of stainless steel SUS304
will be lowest. In the other hand, forming energy is also low and the longevity of the SPIF machine
will be prolonged.
Acknowledgments
This work is funded by Petrovietnam University under grand code number GV1913. We highly
appreciate the great grant from PVU that contributed to achieve this research.
References
[1] Edward Leszak “Apparatus and Process for Incremental Dieless Forming” Patent US3342051,
Ser.No. 388.577 10 Claims (Cl. 72- 81)
[2] P.A.F. Martins, N. Bay, M. Skjoedt, M.B. Silva “Theory of single point incremental forming”,
CIRP Annals - Manufacturing Technology 57, pp 247–252 (2008)
[3] Stainless Steel Grade 304 Atlas Steels Australia
[4] N. Decultot, V. Velay, L. Robert, G. Bernhart, E. Massoni “Behavior modelling of aluminum
alloy sheet for Single Point Incremental Forming”, International Journal of Material Forming1,
Supplement 1 (2008) Pages 1151-1154 DOI: 10.1007/s12289-008-0184-z
[5] DOUGLAS C. MONTGOMERY “Design and Analysis of Experiments” Eighth Edition, John
Wiley & Sons Inc, ISBN 978-1-118-14692-7, 2013
[6] An Introduction to Stress Analysis, Applications with SolidWorks Simulation, Student Guide.
1995-2010, Dassault System SolidWorks Corporation