Murugesan Mohanraj, Yu Jae-Hyeong, Jung Kyu-Seok, Cho Sung-Min, Bhandari Krishna Singh, Lee Chang-Whan
Department of Mechanical System Design Engineering, Seoul National University of Science and Technology, Seoul 01811, Korea.
Department of Mechanical Information Engineering, Seoul National University of Science and Technology, Seoul 01811, Korea.
Materials (Basel). 2022 Feb 16;15(4):1458. doi: 10.3390/ma15041458.
The surface finish is an important characteristic in the incremental sheet forming (ISF) process and is often influenced by numerous factors within the forming process. Therefore, this research was aimed at identifying the optimal forming parameters through the Taguchi method to produce high-quality formed products. The forming tool radius, spindle speed, vertical step increment, and feed rate were chosen as forming parameters in the experimental design, with surface roughness as the response variable. Taguchi L16 orthogonal array design and analysis of variance (ANOVA) test were used to identify the parameter's optimal settings and examine the statistically significant parameters on the response, respectively. Results confirmed that a significant reduction in surface roughness occurred with a drop in vertical step size and an increase in feed rate. In detail, the vertical step size has the most significant influence on the surface roughness, followed by the feed rate and the forming tool radius. In conclusion, the optimum level settings were obtained: forming tool radius at level 3, spindle speed at level 1, vertical step size at level 1, and feed rate at level 4. Additionally, confirmation experiment results based on the optimal settings indicated a good agreement against the experimental observation. Further, the response surface methodology (RSM) was also exploited to devise a mathematical model for predicting the surface roughness. The results comparison confirmed that both techniques could effectively improvise the surface finish.
表面光洁度是增量板材成形（ISF）工艺中的一个重要特性，并且常常受到成形过程中众多因素的影响。因此，本研究旨在通过田口方法确定最佳成形参数，以生产高质量的成形产品。在实验设计中，选择成形刀具半径、主轴转速、垂直步距增量和进给速度作为成形参数，将表面粗糙度作为响应变量。分别使用田口L16正交阵列设计和方差分析（ANOVA）测试来确定参数的最佳设置，并检验对响应具有统计学显著意义的参数。结果证实，随着垂直步距尺寸的减小和进给速度的增加，表面粗糙度显著降低。详细而言，垂直步距尺寸对表面粗糙度的影响最为显著，其次是进给速度和成形刀具半径。总之，获得了最佳水平设置：成形刀具半径为3级，主轴转速为1级，垂直步距尺寸为1级，进给速度为4级。此外，基于最佳设置的验证实验结果与实验观察结果吻合良好。此外，还利用响应面方法（RSM）建立了一个预测表面粗糙度的数学模型。结果比较证实，这两种技术都可以有效地改善表面光洁度。
