Experimental Investigation on Geometric
Accuracy and Surface Roughness
of Formed Part in Multistage Single Point
Incremental Forming (SPIF) Process
Sunandkumar Gajjar, Vikas Sisodia, Rahul Jagtap, Kiran More,
and Shailendra Kumar
Abstract Single point incremental forming (SPIF) process is an advanced dieless
sheet metal forming process in which the requirement of a dedicated punch-die setup
is eliminated. The dedicated punch-die setup is replaced by a universal blank holding
fixture, a punch (or tool), and a backing plate. It has a variety of applications ranging
from automotive to biomedical fields. But its limitations such as inability to form
steeper wall angle and high geometric error in single-stage restricts its application in
sheet metal industries. To overcome this, multistage SPIF process is an alternative
to achieve larger wall angles. Formability in multistage SPIF process is increased
by providing intermediate stages. Various methodologies have been suggested to
enhance the profile accuracy, however, it still remains the major issue. In the present
paper influence of process variables namely feed rate, number of forming stages and
pitch size on geometric accuracy and surface roughness of formed part is investigated.
Taguchi L 18 orthogonal array is used for design of the experiments. From the analysis
of variance (ANOVA), it is found that the number of stages and pitch size have a
significant influence on geometric accuracy and surface roughness. Since feed rate is
an insignificant parameter. So a higher feed rate can be used to reduce forming time.
Further, a mathematical model is developed to predict the geometrical accuracy and
surface roughness of the formed part.
Keywords Single point incremental forming (SPIF) process · Multistage ·
Geometric accuracy · Surface roughness · Wall angle
S. Gajjar
Department of Mechanical Engineering, Parul Institute of Technology, Parul University,
Vadodara, Gujarat 391760, India
V. Sisodia (B) · K. More · S. Kumar
Department of Mechanical Engineering, 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_22
209
Accuracy and Surface Roughness
of Formed Part in Multistage Single Point
Incremental Forming (SPIF) Process
Sunandkumar Gajjar, Vikas Sisodia, Rahul Jagtap, Kiran More,
and Shailendra Kumar
Abstract Single point incremental forming (SPIF) process is an advanced dieless
sheet metal forming process in which the requirement of a dedicated punch-die setup
is eliminated. The dedicated punch-die setup is replaced by a universal blank holding
fixture, a punch (or tool), and a backing plate. It has a variety of applications ranging
from automotive to biomedical fields. But its limitations such as inability to form
steeper wall angle and high geometric error in single-stage restricts its application in
sheet metal industries. To overcome this, multistage SPIF process is an alternative
to achieve larger wall angles. Formability in multistage SPIF process is increased
by providing intermediate stages. Various methodologies have been suggested to
enhance the profile accuracy, however, it still remains the major issue. In the present
paper influence of process variables namely feed rate, number of forming stages and
pitch size on geometric accuracy and surface roughness of formed part is investigated.
Taguchi L 18 orthogonal array is used for design of the experiments. From the analysis
of variance (ANOVA), it is found that the number of stages and pitch size have a
significant influence on geometric accuracy and surface roughness. Since feed rate is
an insignificant parameter. So a higher feed rate can be used to reduce forming time.
Further, a mathematical model is developed to predict the geometrical accuracy and
surface roughness of the formed part.
Keywords Single point incremental forming (SPIF) process · Multistage ·
Geometric accuracy · Surface roughness · Wall angle
S. Gajjar
Department of Mechanical Engineering, Parul Institute of Technology, Parul University,
Vadodara, Gujarat 391760, India
V. Sisodia (B) · K. More · S. Kumar
Department of Mechanical Engineering, 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_22
209