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Modeling and Optimization of Surface Roughness in Incremental Sheet Forming using a Multi-objective Function

机译：使用多目标函数对增量板材成形中的表面粗糙度进行建模和优化

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摘要

As a critical product quality constraint, surface roughness is regarded as a weak point in incremental sheet forming (ISF). It is of great importance to identify the impact of forming parameters on the surface roughness and optimize the surface finish at the production stage. This paper proposes a systematic approach to modeling and optimizing surface roughness in ISF. The quantitative effects of four parameters (step down, feed rate, sheet thickness, and tool diameter) on surface roughness are analyzed using the response surface methodology with Box-Behnken design. The multi-objective function is used to evaluate the overall surface roughness in terms of the tool-sheet contact surface roughness, i.e., internal surface roughness and the noncontact surface roughness, i.e., external surface roughness. Additionally, the average surface roughness (R_a) on each surface is measured along the tool-path step-down direction taking the impact of sheet roll marks into account. The optimal conditions for the minimization of overall surface roughness are determined as step down (0.39 mm), feed rate (6000mm/min), sheet thickness (1.60 mm), and tool diameter (25 mm). This study shows that Box-Behnken design with a multi-objective function can be efficiently applied for modeling and optimization of the overall surface roughness in ISF.
机译：作为产品质量的关键限制，表面粗糙度被视为增量板材成形（ISF）的薄弱环节。识别成型参数对表面粗糙度的影响并在生产阶段优化表面光洁度非常重要。本文提出了一种在ISF中建模和优化表面粗糙度的系统方法。使用具有Box-Behnken设计的响应表面方法，分析了四个参数（降级，进给速度，板材厚度和刀具直径）对表面粗糙度的定量影响。多目标函数用于根据工具板接触表面粗糙度，即内表面粗糙度和非接触表面粗糙度，即外表面粗糙度，来评估整体表面粗糙度。另外，考虑到片材辊痕的影响，沿着刀具路径降下方向测量每个表面上的平均表面粗糙度（R_a）。最小化整体表面粗糙度的最佳条件由降级（0.39 mm），进给速度（6000mm / min），板材厚度（1.60 mm）和刀具直径（25 mm）确定。这项研究表明，具有多目标功能的Box-Behnken设计可以有效地应用于ISF中总体表面粗糙度的建模和优化。

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