This work aims to optimize surface roughness, wall angle deviation, and average wall thickness as output responses of ALuminium-1050 alloy cone formed by the single point incremental sheet metal forming process. The experiments are accomplished based on the use of a mixed level Taguchi experimental design with an L18 orthogonal array. Six levels of step depth, three levels of tool diameter, feed rate, and tool rotational speed have been considered as input process parameters. The analyses of variance (ANOVA) have been used to investigate the significance of parameters and the effect of their levels for minimum surface roughness, minimum wall angle deviation, and maximum average wall thickness. The results indicate that step depth and tool rotational speed are the most significant parameters on the output responses. The predicted optimal values for the surface roughness, average wall thickness, and wall angle deviation are found to be 0.6363 μm, 0.9442 mm, and 0.0994° respectively. The results have been validated by the confirmation of the experiments and found to be 0.57, 0.9162, and 0.124, respectively, which are within the range of these values.
University of Baghdad
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