FLD Analysis and Optimization of Single Point Incremental Forming on Inconel 625 Sheets

Single Point Incremental Forming (SPIF) of sheet metals is an area where industry can focus due to the extensive opportunities available for automated manufacture of sheet metal parts. Single point incremental forming, sheet metal part is formed in a step by step mode by a CNC guided; rotating, spherical tool without using a supporting die. It is a method to deform the sheet metal into different shapes such as straight groove, cup and cone shaped parts with variable wall angles. It is used for the expansion of small scale batches and reform products at a relatively lower cost. So the process is eminently recommended for fast prototyping implementation, but the slowness of the process is a major disadvantage that prevents industries from applying it on a larger scale. SPIF is an advanced technological process, industrial and manufacturing applications mainly in the aerospace and automobile sectors. The objective of this present work is to analyse the SPIF process of Inconel 625 sheets through Forming Limit Diagram and its optimization using response surface methodology. The Inconel blank sheet is clamped in a fixed blank holder and the form describes the contour of the desired geometry controlled by a regular CNC machine. The Forming Limit Diagram FLD of Inconel 625 sheets are plotted. The sheet when formed at 600 rpm and 0.6 mm vertical step depth shows higher major true strain values. Optimization of process parameters using response surface methodology.