ENHANCING FORMABILITY OF AA6061 IN INCREMENTAL SHEET FORMING: EXPLORING PARAMETER EFFECTS ON FRACTURE DEPTH

AA6061's high strength and strain rate sensitivity in Incremental Sheet Forming (ISF) demand precise parameter control to prevent early fractures, especially at steep wall angles. Tool diameter influences the distribution of deformation forces, while spindle speed, step depth, and feed rate control the rate and extent of material deformation, collectively impacting the forming. This paper investigates the effect of these process parameters on the formability in terms of fracture depth. A statistical analysis is performed to identify the significant factors affecting forming depth. The main effect plot suggests that except the spindle speed, all three process parameters influence forming depth. However, the interaction plot reveals a more complex relationship, where step depth has a stronger effect on fracture depth, particularly at higher feed rates. These findings indicate that the interplay between these factors is crucial for determining optimal process parameters, where nearly 10% of increase in forming depth was achieved.