Abstract: “Incremental forming process has become more and more popular because of its ease of forming and capability to produce different part shapes using same machine setup. This paper describes an experimental study on the influence of process parameters in single point incremental forming (SPIF) on the surface roughness of formed part. Experiments are performed on cold rolled steel sheets (DC04) on a 3-axis CNC milling machine. Hemispherical headed tool of high speed steel material is used to study the effect of tool diameter, pitch, feed rate and spindle speed on the surface roughness (Ra) of formed part. Design of experiment full factorial plan is used for experimentation and results are plotted using ANOVA. Based on the experimental results, the equation (model) for Ra is developed using regression analysis. This model can be used to predict surface roughness of part to be formed. Considerable effect of tool diameter and pitch is found on the surface quality of formed part.”

Keywords: Single point incremental forming (SPIF), surface roughness, ANOVA.