Improvement of Surface Roughness in Single Point Incremental Forming Process by the Implementation of Controlled Vibration

Abstract

Vibration implementation that assists metal forming has many advantages, such as enhancement of surface equality, reducing the forming force and decreasing the stresses. The technology of single-point incremental forming with all the above-mentioned advantages has been performed with the vibration. This paper focuses on the average surface roughness (Ra) improvement of the final product by using the vibration. The average roughness was found to be affected by vibration of the sheet metal. The combination of vibration produced a better surface quality of the forming shape by using an active damper to control the vibration. For determining the damping ratio, which gives the necessary roughness, an artificial neural network (ANN) was created based on experimental results. A feed forward neural network with Liebenberg–Marquardt back propagation algorithm was utilized for building the artificial neural network model (3-n-1). Confirmation runs were conducted for verifying the agreement between the predicted results of ANN with those of the experimental outcomes. As a result, the product surface quality is increased where the surface roughness was reduced by (18%) from the surface roughness without vibration. The best reduction rate was in the axial forming force at (100 Hz) frequency, where the reduction rate was about (11.64%) from the force without vibration.

Keywords

• spif
• vibration
• roughness
• ann
• active damper