Investigation of the Effect of Process Parameters on Energy Consumption in Incremental Sheet forming

The selection of machine tool and process parameters plays a crucial role in the energy consumption in manufacturing processes such as incremental sheet forming (ISF) process. The analysis of how the process parameters influence the energy required during ISF processes will not only provide opportunity to reduce the environmental consequences, but also reduce economic cost. To this end, an empirical power model is presented with the aim of understanding energy consumption composition during ISF performed on a milling machine. The effects of process variables (e.g., material strength, step down, sheet thickness, tool diameter, and feed rate) on the power, forming time, and energy required for ISF processes are experimentally investigated. In particular, experimental results are in-depth analyzed to understand energy required breakdown by a machine tool during the ISF. Further, the mechanism on how the process parameters affect the energy required for the sheet plastic deformation is revealed. Based on the analysis above, useful energy-saving suggestions on selecting process parameters are provided.