INFLUENCE OF TOOL DIAMETER IN SINGLE POINT INCREMENTAL FORMING OF POLYMERIC MATERIALS

Single point incremental forming (SPIF) is a versatile and cost-effective manufacturing process used extensively in prototyping and low-batch engineering components.It involves the precise movement of a tool over a thin sheet of material, incrementally deforming it into the desired shape.Process parameters significantly influence the quality and formability of the formed component.Factors such as spindle speed, feed rate, toolpath geometry, and tool dimensions impact material deformation, surface finish, and dimensional accuracy.Optimal parameter selection is critical to avoid defects like springback, wrinkling, tearing, or excessive surface degradation, particularly in polymers.Adjusting these parameters enables SPIF to accommodate a wide range of materials and geometries, making it a versatile manufacturing solution for various industries.The work presented herein investigates the effect of process parameters, namely tool diameter and step size on the formability of polymeric materials.The materials investigated in this study are polycarbonate and nylon 6.A full factorial design of experiments schedule was conducted.Tool diameters varied between 8 mm and 20 mm and step sizes varied between 0.5 mm and 2.0 mm.Feed rate and wall angle remained constant.throughout the experiments.Various measurements took place, such as profile evaluation, thickness distribution, and surface roughness.It was found that in most cases, small tool diameters result in better formability, minimum springback, and more uniform thinning.Additionally, no discernable trend was observed between forming conditions and surface roughness.