Optimization in single point incremental forming of Inconel 718 through response surface methodology

Abstract

Incremental sheet forming is a flexible and versatile process with a promising future in the batch production and prototyping sectors. With decreased design time and negligible production time, incremental sheet forming provides reliability, flexibility, and quality, while being an economical option in contrast to the traditional forming process. In this paper, Inconel 718, a material that has extensive use in aircraft engines, is considered for experimental work to obtain the optimum combination of process parameters. Response surface methodology is used to optimize the process parameters, in particular feed rate, step depth, and lubricant viscosity. The output responses are surface roughness, profile accuracy, and wall thickness. Analysis of variance (ANOVA) is performed using the experimental results to predict the statistical influence of the process parameters. The optimal combination of process parameters is further predicted using a numerical optimization technique to achieve better profile accuracy and surface finish. The results obtained are experimentally validated and are in good agreement with the predicted values.