Optimization of Incremental Forming of Low-Alloy High-Yield-Strength HC300LA Sheet Using a Rolling Blank Holder Method

摘要

Incremental sheet metal forming is a method that enables the fast and flexible production of complex geometric parts using a very simple set of forms. However, this method presents some problems including wall thickness and spring-back. Different methods are developed to solve these problems. One of these, the rolling blank holder method, is applied in this study using a 1 mm-thick HC300LA sheet. The effects of holding pressure, increment size, forming tool diameter, and feed rate parameters on spring-back, wall thickness, surface roughness, and forming force are investigated in the experiments conducted using the two-point incremental forming-rolling blank holder (TPIF-RL) sheet-forming method. The effects of the selected parameters are optimized using response surface methodology. As a result of the study, it is determined that the most important parameter for surface quality and wall thickness is the forming tool diameter, the most effective parameters for forming force are the forming tool diameter and increment size, and for spring-back the dominant parameters are forming tool diameter, holding pressure, and increment size. The spring-back angle increases with increasing forming tool diameter, holding pressure, and feed rate. In addition, both spring-forward and spring-back are observed in the formed parts.