Lubricant Evaluation Technique for Single Point Incremental Forming Process
Article Sidebar
Main Article Content
Abstract
Single-Point Incremental Forming (SPIF) is a highly flexible dieless forming process suitable for small batch production. The higher the feed rate and tool rotational speed, the higher the production rate will be. Therefore, the selection of the suitable lubricant is a key important factor to maintain the formability of the material when increasing the feed rate and tool rotational speed. This paper proposes the technique to evaluate and later on select the proper lubricant for these conditions. This technique was divided into two phases; 1) screening, and 2) stabilization. The screening phase is a quick method for preliminary selection of the lubricants. The stabilizing phase is a step to evaluate the reliability and ensure efficiency of the lubricant throughout the process because of the significant increase in forming temperature, which directly effects lubricant's performance. the performance of the lubricant. Two types of lubricants, namely solid (Graphite) and liquid (Callington Calform NF-206), lubricants mixed with the base oil (coconut oil) at different ratios were tested. The cold rolled hot-dipped zinc-coated steel sheet with a thickness of 0.176 mm. and wall angles of 45, 50, 55, and 60 degrees with the depth of each wall angle of 5 mm was used. During the screening phase, the fifteen mixtures were firstly tested by using the achieved maximum wall angles without fracture as a criterion. Later on, the lubricant mixtures which could successfully form at the wall angle of 60 degrees with the forming depth of 20 mm would be tested in the stabilization phase to evaluate the formability and the forming temperature. The results showed that during the screening phase 11 lubricants could perform successfully, while the stabilization phase with the wall angle of 60 degrees only 3 lubricants could successfully form the workpiece. Therefore, this evaluation technique could help to evaluate and, for later on, be a criterion to select the suitable lubricant.
Article Details
References
R. Aerens, P. Eyckens, A. Van Bael, and J. R. Duflou, “Force prediction for single point incremental forming deduced from experimental and FEM observations,” The International Journal of Advanced Manufacturing Technology, vol. 46, pp. 969–982, 2010.
G. Palumbo and M. Brandizzi, “Experimental investigations on the single point incremental forming of a titanium alloy component combining static heating with high tool rotation speed,” Material and Design, vol. 40, pp. 43–51, 2012.
J. R. Duflou, A. K. Behera, H. Vanhove, and L. S. Bertol, “Manufacture of accurate titanium cranio-facial implants with high forming angle using single point incremental forming,” Key Enginerring Materials, vol. 549, pp. 223–230, 2013.
J. Jeswiet, J. R. Duflou, and A. Szekeres, “Forces in single point and two point incremental forming,” Advanced Materials Research, vol. 6–8, pp. 449–456, 2005.
M. Durante, A. Formisano, A. Langella, and F. M. C. Minutolo, “The influence of tool rotation on an incremental forming process,” Journal of Materials Processing Technology, vol. 209, pp. 4621–4626, 2009.
G. Buffa, D. Campanella, R. Mirabile, and L. Fratini, “Improving formability in SPIF processes through high-speed rotating tool: Experimental and numerical analysis,” Key Engineering Materials, vol. 549, pp. 156–163, 2013.
Y. Kim and J. Park, “Effect of process parameters on formability in incremental forming of sheet metal,” Journal of Materials Processing Technology, vol. 130–131, pp. 42–46, 2002.
D. Xu, B. Lu, T. Cao, J. Chen, H. Long, and J. Cao, “A comparative study on process potentials for frictional stir and electric hot assisted incremental sheet forming,” Procedia Engineering, vol.81, pp. 2324–2329, 2014.
A. Attanasio, E. Ceretti, and C. Giardini, “Optimization of tool path in two points incremental forming,” Journal of Materials Processing Technology, vol. 177, pp. 409–412, 2006.
B. V. Desai, K. P. Desai, and H. K. Raval, “Die-less rapid prototyping process: Parametric investigations,” Procedia Materials Science, vol. 6, pp. 666–673, 2014.
J. R. Patel, K. S. Samvatsar, H. P. Prajapati, and U. M. Sharma, “Analysis of variance for surface roughness produced during single point incremental forming process,” International Journal of New Technologies in Science and Engineering, vol. 2, pp. 90–97, 2015.
S. Kurra and S. Regalla, “Multi-objective optimization of single point incremental sheet forming using Taguchi-based grey relational analysis,” International Journal of Materials Engineering Innovation, vol. 6, pp. 74–90, 2015.
P. B. Uttarwar, S. K. Raini, and D. S. Malwad, “Optimization of process parameter on surface roughness (Ra) and wall thickness on SPIF using Taguchi method,” International Research Journal of Engineering and Technology, vol. 2, no. 9, pp. 781–784, 2015.
R. Jagtap, S. Kashid, S. Kumar, and H. M. A. Hussein, “An experimental study on the influence of tool path, tool diameter and pitch in single point incremental forming (SPIF),” Advances in Materials and Processing Technologies, vol. 1, no. 3–4, pp. 465–473, 2015.
D. S. Malwad and V. M. Nandedkar, “Deformation mechanism analysis of single point incremental sheet metal forming,” Procedia Materials Science, vol. 6, pp. 1505–1510, 2014.
H. Wei, G. Hussain, A. Iqbal, and Z. P. Zhang, “Surface roughness as the function of friction indicator and an important parameters-combination having controlling influence on the w: Resent results in incremental forming,” The International Journal of Advanced Manufacturing Technology, vol. 101, pp. 2533–2545, 2019, doi: 10.1007/ s00170-018-3096-1.
J. A. Schey, “Tribology in metal working friction, lubrication and wear,” in American Society for Metals. Ohio: Metals Park, 1984, pp. 16–21.
C. Xu, Y. Li, Z. Wang, Z. Cheng, and F. Liu, “The influence of self-lubricating coating during incremental sheet forming of TA1 sheet,” The International Journal of Advanced Manufacturing Technology, vol. 110, pp. 2465–2477, 2020.
B. Lu, Y. Fang, D. K. Xu, J. Chen, H. Ou, N. H. Moser, and J. Cao, “Mechanism investigation of friction-related effects in single point incremental forming using a developed oblique roller-ball tool,” International Journal of Machine Tools and Manufacture, vol. 85, pp. 14–29, Oct. 2014.
D. Xu, W. Wu, R. Malhotra, J. Chen, B. Lu, and J. Cao, “Mechanism investigation for the influence of tool rotation and laser surface texturing (LST) on formability in single point incremental forming,” International Journal of Machine Tools and Manufacture, vol. 73, pp. 37–46, 2013.
D. Adams and J. Jeswiet, “Single-point incremental forming of 6061-T6 using electrically assisted forming methods,” Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacturing, vol. 228, no. 7, pp. 757–746, 2014.
M. Dwivedy and V. Kalluri, “The effect of process parameters on forming forces in single point incremental forming,” Procedia Manufacturing, vol. 29, pp. 120–128, 2019.
P. Gupta and J. Jeswiet, “Effect of temperatures during forming in single point incremental forming,” The International Journal of Advanced Manufacturing Technology, vol. 95 pp. 3693– 3706, 2018.
I. Bagudanch, G. Centeno, C. Vallellano, and M. L. Garcia-Romeu, “Forming force in single point incremental forming under different bending conditions,” Procedia Engineering, vol. 63, pp. 354– 360, 2013
C. Xu, Y. Li, Z. Wang, Z. Cheng, and F. Liu, “The influence of self-lubricating coating during incremental sheet forming of TA1 sheet,” The International of Advanced Manufacturing Technology, vol. 110, pp. 2465–2477, 2020.
Z. Chang and J. Chen, “Analytical model and experimental validation of surface roughness for incremental sheet metal forming parts,” International Journal of Machine Tools and Manufacture, vol 146, p. 103453, 2019
M. B. Silva, P. S. Nielsen, N. Bay, and P. A. F. Martins, “Failure mechanism in single-point incremental forming of metals,” International Journal Advance Manufacturing Technology, vol. 56, pp. 893–903, 2011.
S. Golabi and H. Khazaali, “Determining frustum depth of 304 stainless steel plates with various diameters and thicknesses by incremental forming,” Journal of Mechanical Science and Technology, vol. 28, no. 8, pp. 3273–3278, 2014.
T. Altan and A. E. Tekkaya, “Incremental sheet forming” in Sheet Metal Forming Process and Applications. Ohio: ASM International Material Park, 2012, pp. 273–288.
J. Jeswiet, F. Micari, G. Hirt, A. Bramley, J. Duflou, and J. Allwood, “Asymmetric single point incremental forming of sheet metal,” CIRP Annals, vol. 54, pp. 623–649, 2005.
J. Jeswiet, D. Adams, M. Doolan, T. McAnulty, and P. Gupta, “Single point and asymmetric forming,” Advance Manufacture, vol. 3, pp. 253–262, 2015.
Hot-Dip Zinc-Coated Cold-Rolled Steel Coil, Sheet and Corrugated Sheet, TIS 50-2548, Nov. 2005.
Cold-reduced Carbon Steel Sheets and Strips, JIS G 3141, 2005.
C. Tavichaiyuth, Y. Aue-u-Lan, and T. Hart- Rawung, “Evaluation of forging die defect by considering plastic deformation and abrasive wear in a hot forged axle shaft,” Applied Science and Engineering Progress, vol. 14, no. 1, pp. 60–71, 2021, doi: 10.14416/j.asep.2020.12.005.
N. Sae-eaw and Y. Aue-u-lan, “Friction evaluation for combined drawing and ironing process with thick sheet by ball ironing,” Journal of Manufacturing Science and Engineering, vol. 143, 2020, Art. no. 061004.