SHEA CHENG KUANG - Universiti Malaysia Pahang

DIELESS INCREMENTAL FORMING USING

3-AXIS CNC MILLING MACHINE

FOR ALUMINIUM SHEET

SHEA CHENG KUANG

B. ENG. (HONS.) MANUFACTURING ENGINEERING

UNIVERSITI MALAYSIA PAHANG

DIELESS INCREMENTAL FORMING USING

3-AXIS CNC MILLING MACHINE

FOR ALUMINIUM SHEET

SHEA CHENG KUANG

Report submitted in partial fulfilment of the requirements

for the award of the degree of

Bachelor of Engineering in Manufacturing Engineering

Faculty of Manufacturing Engineering


JUNE 2016


DECLARATION OF THESIS AND COPYRIGHT

Author’s Full Name : ____________________________________________

Identification Card No : ____________________________________________

Title : ____________________________________________

_____________________________________________

Academic Session : ____________________________________________

I declare that this thesis is classified as:

CONFIDENTIAL

(Contains confidential information under the

Official Secret Act 1972)

RESTRICTED

(Contains restricted information as specified by

the organization where research was done)*

OPEN ACCESS

I agree that my thesis to be published as online

open access (Full text)

I acknowledge that Universiti Malaysia Pahang reserve the right as follows:

1. The Thesis is the Property of University Malaysia Pahang.

2. The Library of University Malaysia Pahang has the right to make copies for the purpose

of research only.

3. The Library has the right to make copies of the thesis for academic exchange.

Certified by:

_____________________________ _____________________________

(Author’s Signature) (Supervisor’s Signature)

_________________________________

Name of Supervisor

Date: _______________ Date: ________________

iii

SUPERVISOR’S DECLARATION

I hereby declare that I have checked this thesis and in my opinion, this thesis is adequate

in terms of scope and quality for the award of the degree of Bachelor of Engineering in

Manufacturing.

Signature :

Name of supervisor : DR ZAMZURI BIN HAMEDON

Position : SENIOR LECTURER / DEPUTY DEAN

Date :

iv

STUDENT’S DECLARATION

I hereby declare that the work in this thesis is my own except for quotation and summaries

which have been duly acknowledged. The thesis has not been accepted for any degree

and is not concurrently submitted for award of other degree.

Signature :

Name : SHEA CHENG KUANG

ID Number : FA12052

Date :

viii

TABLE OF CONTENTS

Page

SUPERVISOR’S DECLARATION iii

STUDENT’S DECLARATION iv

ACKNOWLEDGEMENTS v

ABSTRACT vi

ABSTRAK vii

TABLE OF CONTENTS viii

LIST OF TABLES x

LIST OF FIGURES xiii

LIST OF SYMBOLS xv

LIST OF ABBREVIATIONS xvi

CHAPTER 1 INTRODUCTION

1.1 Introduction 1

1.2 Project Background 1

1.3 Problem Statement 3

1.4 Objectives 4

1.5 Project Scopes 4

CHAPTER 2 LITERATURE REVIEW

2.1 Introduction 5

2.2 Mechanics of Incremental Sheet Forming 5

2.3 Influence of Tool Diameter 7

2.4 Influence of Wall Angle 8

2.4.1 Sine Law 10

2.5 Influence of Feed Rate 11

2.6 Influence of Step Size 12

ix

CHAPTER 3 METHODOLOGY

3.1 Introduction 13

3.2 Flow Chart of the Project 14

3.3 Design of Experiment 15

3.4 Materials and Equipment 19

3.4.1 Bill of Materials 19 3.4.2 Machines and Equipment 19

CHAPTER 4 RESULT ANALYSIS AND DISCUSSIONS

4.1 Introduction 22

4.2 Data Collection 24

4.2.1 Surface Roughness 24 4.2.2 Thickness Reduction 35

4.3 Data Analysis 41

4.3.1 ANOVA for Surface Roughness 42 4.3.2 ANOVA for Thickness Uniformity 48

4.3.4 Parameters Optimisation for Surface Roughness 50 4.3.5 Parameters Optimisation for Uniform Thickness Reduction 60 4.3.7 Confirmation Test 62

4.4 Discussions 63

4.4.1 Surface Roughness 63

4.4.2 Thickness Uniformity 65

CHAPTER 5 CONCLUSIONS AND RECOMMENDATIONS

5.1 Conclusions 67

5.2 Recommendations 68

REFERENCES 69

APPENDICES

A1 Gantt Chart of FYP 1 71

A2 Gantt Chart of FYP 2 72

B1 G-code of optimum parameters for minimum surface roughness 73

B2 G-code of optimum parameters for uniform thickness reduction 81

x

LIST OF TABLES

Table No. Title Page

3.1 Process parameters and level descriptions 17

3.2 Design of experiment plan 17

3.3 Bill of Materials 19

3.4 Equipment used and their respective locations 19

4.1 Average surface roughness of aluminium sheet in ISF for Experiment 1 24









4.10 Summary of average surface roughness of aluminium sheet in ISF 33

4.11 Average surface roughness of each corner of pyramid frustum in ISF 34

4.12 Thickness reduction of aluminium sheet for Experiment 1 36







xi



4.21 Summary of thickness reduction of aluminium sheet in ISF 38

4.22 Experimental and theoretical thickness reduction of aluminium sheet in ISF 40

4.23 Means and S/N ratios for surface roughness 42

4.24 ANOVA for means (surface roughness) 42

4.25 ANOVA for S/N ratios (surface roughness) 43

4.26 Means and S/N ratios for surface roughness of R5 43

4.27 ANOVA for means (SR of R5) 44

4.28 ANOVA for S/N ratios (SR of R5) 44










4.38 Means and S/N ratios for thickness uniformity 48

4.39 ANOVA for means (thickness uniformity) 48

4.40 ANOVA for S/N ratios (thickness uniformity) 49

4.41 Response table for S/N ratio of surface roughness (smaller is better) 51

4.42 Response table for means (surface roughness) 51

4.43 Response table for S/N ratio of surface roughness of R5 (smaller is better) 53

xii

4.44 Response table for means (surface roughness of R5) 53


4.46 Response table for means (surface roughness of R10) 55


4.48 Response table for means of surface roughness of R15 57


4.50 Response table for means of surface roughness of R20 59

4.51 Response table for S/N ratio of thickness uniformity (smaller is better) 61

4.52 Response table for means (thickness uniformity) 61

4.53 Optimised parameters for each outcome 62

4.54 Average surface roughness of aluminium sheet for optimised parameters 62

4.55 Comparison of actual surface roughness with the predicted value 63

xiii

LIST OF FIGURES

Figure No. Title Page

1.1 Example of Single Point Incremental Forming (SPIF) 2

1.2 Example of Two Point Incremental Forming (TPIF) 2

2.1 Working principle of incremental sheet forming 6

2.2 Negative forming and positive forming 7

2.3 Thickness strain vs depth at different wall angle 8

2.4 Force curve for wall angles of 20º to 60º 9

2.5 Deformation of sheet in ISF and parameters of sine law 10

2.6 Surface finish for step size 0.2 mm and 0.5 mm 12

3.1 Turning machine 15

3.2 Forming tool for ISF 15

3.3 Complete structure of blank holder for ISF 16

3.4 CNC milling machine 16

3.5 Sketch of pyramid frustum shape of aluminium sheet in CATIA 18

3.6 Tool path generation in CATIA 18

3.7 Experiment setup for ISF on CNC milling machine 18

3.8 Vertical band saw 20

3.9 Surface roughness tester 20

3.10 Microscope profile video measuring system 21

4.1 Top view of an aluminium sheet after ISF 22

4.2 Overview of the aluminium sheet after ISF 23

4.3 Bottom view of the aluminium sheet after ISF 23

4.4 Surface of aluminium sheet for Experiment 1 24

xiv









4.13 Comparison of average surface roughness of aluminium sheet in ISF 33

4.14 Average surface roughness of each corner of pyramid frustum in ISF 35

4.15 Average surface roughness and thickness uniformity of aluminium sheet 39

4.16 Actual and theoretical thickness reduction of aluminium sheet in ISF 40

4.17 Response graph for S/N ratios and means for surface roughness 50

4.18 Response graph for S/N ratios and means for surface roughness of R5 52




4.22 Response graph for S/N ratios and means for thickness uniformity 60

4.23 Surface of aluminium sheet with 1500 rpm spindle speed 64

4.24 Formation of surface waviness in ISF 65

4.25 Interface of Precision Plotter software 66

xv

LIST OF SYMBOLS

n Number of observations

t0 Initial thickness of sheet

t1 Final thickness of sheet

y Response

α Wall angle

xvi

LIST OF ABBREVIATIONS

A Angle

ANOVA Analysis of Variance

CAD Computer-aided design

CAM Computer-aided manufacturing

CNC Computer Numerical Control

DF Degree of freedom

DOE Design of experiment

F Ratio of variance of a source to the variance of error

FR Feed rate

FYP Final year project

ISF Incremental sheet forming

MS Mean squares

NC Numerical control

RPM Revolution per minute

S/N Signal-to-noise

SPIF Single point incremental forming

SR Surface roughness

SS Step size

SS Sum of squares

TPIF Two point incremental forming

TU Thickness uniformity

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SHEA CHENG KUANG - Universiti Malaysia Pahang