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Go to Editorial ManagerIncremental forming is a flexible sheet metal forming process which performed by utilizes simple tools to locally deform a sheet of metal along a predefined tool path without using of dies. One limitations of single point incremental forming (SPIF) process is the error occur between the CAD design and the product profile. This work presents the single point incremental forming process for produced pyramid geometry and studied the effect of tool geometry, tool diameter, wall angle, and spindle speed on the dimensional accuracy. Three geometries of forming tools were used in experimental work: ball end tool, hemispherical tool, and flat with round corner tool. The sheet material used was pure Aluminum (Al 1050) with thickness of (0.9 mm). The experimental tests in this work were done on the computer numerical control (CNC) vertical milling machine. The products dimensions were measured by utilized the dimensional sensor measuring instrument. The extracted results from the single point incremental forming process indicated the best acceptance between the CAD profile and product profile was found with the ball end tool and diameter of (10 mm), wall angle (50°) and the rotational speed of the tool was (800 rpm).
In this work, Aluminum alloy (AA2024-T3) was welded by friction stir (FSW) method using different pin profile design types; straight cylinder, threaded cylinder, tapered cylinder hexagonal, square, and threaded taper. For each type, a flat and concave shoulder was used, as well as, the welding process was single and double. The results of mechanical tests are analyzed using design of experiments method (DOE). The best and weaken mechanical properties (tensile strength, bending force and hardness) are observed when the welding is achieved by hexagonal and straight cylinder pin profile respectively. A concave shoulder gave higher mechanical properties as compared with flat shoulder. The change in welding process type presented a sensible effect. Nugget zone hardness is higher than that of base metal for all specimens. The optimum hardness result is recorded by hexagonal pin with concave shoulder profile.