Optimization, finite element simulation, fractography and tool wear analysis during SPIF process of perforated stainless steel sheets

The paper deals with an investigation on the single point incremental forming (SPIF) of perforated SS 304 L sheet, to optimize various input parameters, perform the finite element simulation of the SPIF using optimum process setting, conduct fractographic analysis, and to do the wear analysis of the forming tool. The study was conducted with 18 experiments as per Taguchi’s orthogonal array, to evaluate the impact of input parameters on responses. Straight groove and wall angle tests were performed separately, to obtain the maximum sum of strains (Σε)max and maximum wall angle (ϕmax) respectively. The tool wear in terms of reduction in length was measured using a profile projector. The optimization was carried out using the Taguchi grey relational analysis (TGRA). ANOVA was employed to share out the variability brought on by the input parameters. The optimal set of forming parameters was identified, and the confirmation experiment served to confirm it. The effect of all input parameters on the responses were studied referring to the main effect plots. The tool was hardened to bring down the wear and it was confirmed by performing the experiment. FE simulation was done using Abaqus software and the results were in better agreement with that of the experiment. SEM micrographs were taken, analyzed and the fracture mode was identified to be ductile.