Wall Angle Test Lab Report

The Experiments were performed to analyze the effect of wall angle, step size, and tool diameter, spindle speed and feed rate on formability of commercial aluminum alloy. At initial stage experiments were carried out by using material AA8011. Constant angle test was designed to evaluate the formability of material at an angle 550, 650 and 750. During these experiments, spindle speeds of 1000 rpm and feed rate of 1500 mm/min were held constant throughout the experiments. All the parts were formed in a cone shape with a diameter of 94 mm and to achieve the depth of 50 mm. Following table III shows the variable parameter combination during the experiments. For AA8011 experiments were formed according to L9 orthogonal array to obtain the quantitative values of response parameters. The orthogonal array is generally used to minimize the cost of experimentation and process time and meaning optimisation results should comes out.

Table III
Single point incremental forming parameter and their levels

Factors Unit Level 1 Level 2 Level 3
Wall angle degrees 55 65 45
Step increment mm 0.2 0.5 1
Feed rate mm/min 500 800 1200
Spindle speed rpm 600 800 1000

The experimental work is also carried out to validate simulation results. The ASTM E8 standard is used to carry out the tensile testing. The load cell is a strain gauge based type with full wheat-stone bridge

This condition is applied because sheet metal is not allowed to slide from clamping area and which leaves the clamping area elements free to rotate around x, y, z-axes. The interaction between tool and sheet are given through general contact algorithm. Coloumb’s friction law is implemented through the mechanical option of interaction properties. Friction value equal to 0.1 is considered. The similar conditions were maintained for the actual experimental