Optimizing process parameters for enhanced formability and fracture behavior in single point incremental forming of SS310 sheets

Abstract

This research investigates the forming and fracture behavior of stainless steel 310 Grade sheets using the single point incremental forming (SPIF) process under various parameters: ball diameter, spindle speed, feed rate, and vertical step down. Employing an L9 orthogonal array suggested by Taguchi, the study evaluates formability through stress and strain-based forming limit diagrams (FLD). Structural changes were analyzed using scanning electron microscopy fractography and optical microscopy. The highest level of formability was identified at the spindle speed of 100 rpm, feed rate of 600 mm/min, ball diameter of 12 mm, and a vertical step-down of 0.3 mm. Formability analysis is given variations with a maximum of 0.931 at a wall angle of 72.71°, and minimum and medium values of 0.423 and 0.63 at all angles of 60° and 66.24°, respectively. The least and most moderate formability levels showed an 11% variation, and the least and highest formability limits had a 21% higher formability limit. The stress-based limits also increased by 10% for moderate to better formability. The findings indicate that formability increases with lower vertical step down and feed rate, as well as higher spindle speed and ball diameter. This study provides valuable insights into optimizing SPIF process parameters to enhance the quality and structural integrity of formed SS310 components.