Multi-objective optimization of quality characteristics in single point incremental forming process by response surface methodology

Abstract

Single point incremental forming (SPIF) process has demonstrated its capability for sheet metal prototyping and low volume production applications. However, it is not widely used in industries due to poor surface quality and non-uniform thickness distribution of the parts formed by this process. In the present work, a systematic approach has been proposed for modeling and optimizing the surface roughness and minimum thinning to improve the surface finish and uniform thickness profile. With the use of response surface methodology along with Box–Behnken design, the quantitative effects of four parameters (step depth, spindle speed, tool diameter, and wall angle) have been analyzed on surface roughness and minimum thinning. On the basis of response surface methodology and analysis of variance, the optimal results have been predicted. A major interaction has been adequately and proficiently identified to produce minimum surface roughness and uniformly formed thickness profile. © 2019, National Institute of Science Communication and Information Resources (NISCAIR).