OPTIMIZATION OF SINGLE POINT INCREMENTAL FORMING (SPIF) PROCESS PARAMTERS ON SPRINGBACK OF DISSIMILAR FRICTION STIR WELDED ALUMINIUM ALLOYS BLANK USING TAGUCHI METHOD

Abstract

Single-point incremental forming (SPIF) is a die-free sheet metal-forming approach where various profiles can be produced distinctively. However, geometrical defects such as a springback occur during the process and are difficult to control, hence causing assembly errors. This issue becomes more critical for sheets that consist of dissimilar metal joints joined together using the friction stir welding process. This paper investigated the effect of single-point incremental forming (SPIF) parameters such as rotational speed, feed rate, step size, and wall angles on the springback. In this study, a truncated cone profile made of AA 6061 and AA 5052 was studied. The Taguchi method was utilised to identify the most significant effects and optimal SPIF process parameters. The results showed that the wall angle had the most significant effect on the springback compared to others. Based on the ANOVA, the percentage contribution of wall angle was the highest for both sides, which are 93.63% and 89.68%, respectively, compared to other parameters.