فهرست نشریات علمی دسترسی آزاد ایران

This research examined the formability and thickness distribution in incremental sheet forming (ISF) of annealed AL 5052 alloy. In ISF, material formability is primarily measured by the maximum achievable wall angle and the maximum allowable thinning. The maximum wall angle is generally obtained by forming truncated cones and square pyramids with various wall angles until failure, which requires a large number of experiments. Therefore, in the present study, two circular truncated cones and two continuous truncated cones with continuously increasing wall angles (CF-CIWA) were used to predict the maximum wall angle and maximum forming depth while minimizing the number of experiments. The CF-CIWA method was generated using circular, parabolic, elliptical, and exponential generators. In addition, the formability of AL5052 was evaluated using the ISF process and strain-based forming limit curves. The results of the failure heights obtained from the experimental and numerical tests showed good agreement. To achieve the maximum allowable thinning, the thickness distribution was calculated based on the sine law and finite element simulation. The simulated and sine-law thickness values were compared with the measured thickness values. The results indicate that annealed AL 5052 parts can be easily formed by the ISF process using a multi-stage method starting from a 30-degree wall angle up to a wall angle of 78 degrees or less, whereas in the multi-stage method starting from 60 degrees or higher, failure occurs during gradual forming. This research introduces an innovative CF-CIWA (Frustums with Incremental Wall Angle) approach, significantly reducing the number of required experiments to accurately predict forming limit curves.