成形质量差是制约单点增量成形技术发展和商业化的主要因素之一,成形质量包括成形件的表面质量和几何误差.以典型圆锥形制件为研究对象,采用Box-Behnken Design实验方法,设计四因素三水平实验方案,利用响应面法研究工具头直径、层间距、板厚和成形角对表面粗糙度和几何误差的影响,并分别建立表面粗糙度和几何误差的二阶响应模型,最后利用响应模型分别对表面粗糙度和几何误差进行独立和同步优化.结果表明,层间距和板厚分别是影响表面粗糙度和几何误差最显著的因素.使表面粗糙度和几何误差同步最优的工艺参数组合为工具头直径16.0 mm、层间距0.5 mm、板厚0.57 mm、成形角65°,此时表面粗糙度和几何误差分别为0.97 μm和1.939 mm.%The poor forming quality is still one of the biggest challenge for the development and commercialization of single point incremental forming,the forming quality include surface quality and geometric error.In this paper,the cone shape is taken as the research object,Box-Behnken design for cone parts forming have been performed,where four factors and three levels were considered as the experiment scheme.The effects of the four input parameters (tool diameter,step down,sheet thickness and wall angle) on the two outputs including surface roughness and geometric error had been investigated,each of them are predicted by using quadratic equations,then the independent and simultaneous optimization has been used for the present models.It can be concluded that the step down presented the most significant liner effects on surface roughness,while sheet thickness to geometric error.With the target of minimal synchronization of surface roughness and geometric error,which are 0.97 μm,1.939 mm,four processing parameters were optimized with tool diameter as 16 mm,step down as 0.5 mm,sheet thickness as 0.57 mm and wall angle as 65° respectively,under such circumstances.
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