Study on the formability of AISI 430 stainless steel sheet utilizing the incremental sheet forming

In this thesis study, the formability of AISI 430 stainless steel sheets was experimentally investigated using the incremental sheet forming (ISF) method. The aim of the study is to determine the effects of different process parameters on the sheet forming process and to identify the optimal parameters. The experiments were conducted on a CNC vertical milling machine, utilizing variable parameters such as toolpath strategies, feed rate, step down distance, cooling methods, and fixture configurations. In the experimental studies, toolpath strategies including Z Level, helical, and concentric zigzag were employed. Feed rates were set at 750, 1500, and 3000 mm/min, while step down distances were selected as 0.5, 1, and 1.5 mm. Fixture configurations were structured as single point and two-point (female support die). Cooling methods included dry, oily, and air cooling techniques. Tool rotational speeds were determined as idle, 100 rpm, and 200 rpm. While these parameters were selected as variable parameters, the following were considered as constant parameters: AISI 430 sheet material, semi-spherical tool geometry with a diameter of Ø12 mm and a cutting edge radius of R5 mm, truncated cone forming geometry with a 45° wall angle, HSS tool material, progression in the clockwise direction, tool rotation direction, and a sheet thickness of 0.6 mm. SB 5016 was chosen as the oil material. Utilizing the data obtained from the experiments, the Taguchi method and ANOVA test were employed to reach optimal values that ensure formability in ISF process. This study highlights the importance of determining optimal process parameters in ISF operations and the findings provide valuable insights for industrial applications.