Decoding dimensional accuracy by optimization of SPIF of beryllium copper using RSM-DFA

Purpose This research work aims to focus on the concurrent optimization of the process variables in Single-Point Incremental Forming of beryllium copper using amalgamation of Response Surface Methodology analysis with desirability function analysis. Design/methodology/approach The four scrutinized input parameters are step size, feed rate, wall angle and tool rotation speed. In this study, how changes in these four parameters affected the dimensional accuracy of forming shape (truncated cone) in terms of roundness and concentricity is examined. Findings After testing different levels of these parameters, the optimal setting using desirability function analysis was 0.4 mm step size, 200 mm/min feed rate, 45° wall angle and a tool rotation speed of 1,500 rpm with desirability of 99.3%, which is highly close to ideal value of 100%. Practical implications Beryllium copper is frequently used in electrical components due to its excellent conductivity and high strength and other high-performance applications for its superior strength. Originality/value It has been suggested that to enhance dimensional accuracy, minimum step size, high tool rotation speed, lower wall angle and low feed rate must be used. Step size had the most profound impact on dimensional accuracy subsequently followed by feed rate and tool rotation speed, respectively.