Experimental analysis on formability of Cupro-Nickel (90/10 Cu-Ni) during single point incremental forming process

Sheet metal forming is the process of stretching the sheet blank between punch and die. A decade ago punch-stretching experiments were conducted to find the mechanical properties of any sheet metals. At present, Single Point Incremental Forming Process (SPIF), which is an adaptable forming process where the tool is moved in a programmed path and deepened incrementally till the fracture occurs. The increased forming limit, flexibility, reduced forming force and low initial cost this process is gaining importance nowadays. In this paper a detailed investigation on effects of the step depth and formability, chemical analysis, microstructure, tensile test, straight groove tests using (hemispherical and ball attached) tool were carried out for Cu-Ni (90/10) alloy by incremental forming process. The Cu-Ni (90/10) (C70600) alloy with an alpha phase structure has Fe, Mn, Co, P, Pb, Zn, and Sn in considerable weight %. When nickel is amalgamated with copper it shows improvement in durability, alloy’s strength and improvement in tensile strength and good ductility in annealed condition. The Straight groove test (SGT) was conducted with two types of tool along the standard three directions (0°, 45° and 90°) respectively for a length of 40 mm and the strain were measured near the fracture. along the groove (plane strain) and also at the ends (bi-axial strain). The Strain and Stress Based Forming-Limit-Diagram (FLD) were plotted by taking the major and minor strain values along the X and Y-axis and Scanning Electron Microscope (SEM) image with Energy Dispersive X-ray Spectroscopy (EDS) analysis is also carried out to analyse the fracture behaviour of the formed sheet by incremental forming process. Sheet metal forming innovations are the main driving force behind the automotive industries.