Ismail, M. N. B. M., Wen, D. L. W., Meenashisundaram, G. K., Fong, K. S., & Kumar, A. S. (2025). Effects of process parameters on forming forces and surface quality in Micro-Single-Point incremental forming. Journal of Manufacturing Science and Engineering, 147(11). https://doi.org/10.1115/1.4069879
Abstract:
Micro-Single-Point Incremental Forming, the process of shaping parts with at least two
dimensions smaller than 1 mm, is a promising microfabrication technique known for its
near-net-shape capability and high productivity. The growing trend of miniaturization
across various industries has led to increased demand for microproducts and microdevices.
The influence of forming parameters is critical for improving metal formability as well as
enhancing geometrical accuracy and productivity. Accordingly, this article aims to
examine the influence of forming parameters, such as spindle speed and feed rate, on
mean forming forces, force deviations, and their subsequent effects on the surface quality
of 304 stainless steel parts fabricated using single-point incremental forming. Experiments
were conducted using 304 stainless steel foils of thickness, formed with slender forming
tools featuring ball-nose tips of 3 mm and 1 mm diameters, both with a tool height of
12.5 mm. Frustum pyramids were formed with edge radii of 500 μm and step-down of
100 μm, with varying spindle rotation and feed speeds. The surface quality was analyzed
quantitatively using a handheld stylus profilometer and force data of the formed surfaces.
This systematic approach helped identify the optimal forming parameters for slender tool
applications in μSPIF. The optimal parameters determined were a tool speed of
6000 rpm and a feed rate of 750 mm/min. The results were experimentally verified
through the successful forming of a two-shaped geometry comprising a hybrid pyramid
and cone geometry using the identified tool speed and feed rate.
License type:
Publisher Copyright
Funding Info:
This research / project is supported by the A*STAR - Industry Alignment Fund – Pre-Positioning - (MMNH) program
Grant Reference no. : M22K5a0045