Experimental Investigation on Geometric
Error in Single-Point Incremental
Forming with Dummy Sheet
Vikas Sisodia, Shailendra Kumar, Rahul Jagtap, and Kiran More
Abstract Single-point incremental forming (SPIF) process is an emerging sheet
metal forming process in which constraint of using dedicated press tools is eliminated. Some process limitations like poor surface finish, longer forming time, higher
geometrical error, and uneven wall thickness distribution restrict its applicability
in sheet metal industry. But SPIF process with dummy sheet has the capability to
overcome some of the prevailing limitations of SPIF process. In the present paper,
influence of dummy sheet thickness, step size, wall angle, and feed rate on geometrical error in terms of root-mean-squared error (RMSE) of formed part is investigated.
Box Behnken design is used to design the experiments. From the analysis of experimental result, it is found that dummy sheet thickness, step size, and wall angle are
significant process parameters influencing RMSE. No significant influence of feed
rate on RMSE is observed. RMSE increases with increase in dummy sheet thickness
and wall angle, while it decreases with increases in step size. As feed rate increases,
there is nominal decrease in RMSE which is desirable. So higher feed rate is recommended to reduce forming time. Further, empirical model is developed to predict
RMSE. Also, optimization of process parameters is performed to minimize RMSE.
Confirmation experiments were performed in order to check the accuracy of developed predictive model and it is found that predicted results are in good agreement
with experimental results.
Keywords Single-point incremental forming (SPIF) process · Wall angle · Step
size · Geometric error · Root-mean-squared error (RMSE) · Dummy sheet
V. Sisodia (B) · S. Kumar · K. More
Mechanical Engineering Department, Sardar Vallabhbhai National Institute of Technology, Surat,
Gujarat 395007, India
e-mail: vikas.singh619@gmail.com
R. Jagtap
School of Mechanical Engineering, MIT World Peace University, Pune, Maharashtra 411038,
India
© The Editor(s) (if applicable) and The Author(s), under exclusive license
to Springer Nature Singapore Pte Ltd. 2021
N. Gascoin and E. Balasubramanian (eds.), Innovative Design, Analysis
and Development Practices in Aerospace and Automotive Engineering, Lecture Notes
in Mechanical Engineering, https://doi.org/10.1007/978-981-15-6619-6_9
81
Error in Single-Point Incremental
Forming with Dummy Sheet
Vikas Sisodia, Shailendra Kumar, Rahul Jagtap, and Kiran More
Abstract Single-point incremental forming (SPIF) process is an emerging sheet
metal forming process in which constraint of using dedicated press tools is eliminated. Some process limitations like poor surface finish, longer forming time, higher
geometrical error, and uneven wall thickness distribution restrict its applicability
in sheet metal industry. But SPIF process with dummy sheet has the capability to
overcome some of the prevailing limitations of SPIF process. In the present paper,
influence of dummy sheet thickness, step size, wall angle, and feed rate on geometrical error in terms of root-mean-squared error (RMSE) of formed part is investigated.
Box Behnken design is used to design the experiments. From the analysis of experimental result, it is found that dummy sheet thickness, step size, and wall angle are
significant process parameters influencing RMSE. No significant influence of feed
rate on RMSE is observed. RMSE increases with increase in dummy sheet thickness
and wall angle, while it decreases with increases in step size. As feed rate increases,
there is nominal decrease in RMSE which is desirable. So higher feed rate is recommended to reduce forming time. Further, empirical model is developed to predict
RMSE. Also, optimization of process parameters is performed to minimize RMSE.
Confirmation experiments were performed in order to check the accuracy of developed predictive model and it is found that predicted results are in good agreement
with experimental results.
Keywords Single-point incremental forming (SPIF) process · Wall angle · Step
size · Geometric error · Root-mean-squared error (RMSE) · Dummy sheet
V. Sisodia (B) · S. Kumar · K. More
Mechanical Engineering Department, Sardar Vallabhbhai National Institute of Technology, Surat,
Gujarat 395007, India
e-mail: vikas.singh619@gmail.com
R. Jagtap
School of Mechanical Engineering, MIT World Peace University, Pune, Maharashtra 411038,
India
© The Editor(s) (if applicable) and The Author(s), under exclusive license
to Springer Nature Singapore Pte Ltd. 2021
N. Gascoin and E. Balasubramanian (eds.), Innovative Design, Analysis
and Development Practices in Aerospace and Automotive Engineering, Lecture Notes
in Mechanical Engineering, https://doi.org/10.1007/978-981-15-6619-6_9
81