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<p>Experimental research plays a central role in advancing modern manufacturing by validating theoretical models and guiding the development of improved forming processes. This study examines the influence of critical process parameters on forming force (FF) and fracture height (<i>H</i>) in heat-assisted single point incremental forming (HA-SPIF) of AA1050 aluminum alloy sheets. A novel uniform heating method was implemented to stabilize thermal conditions and improve material deformation behavior. The effects of wall angle, forming temperature, tool diameter, and vertical step size were systematically analyzed using a Taguchi L9 design of experiments coupled with analysis of variance (ANOVA). Multi-objective optimization was then performed through Grey Relational Analysis (GRA), targeting the simultaneous minimization of FF and maximization of <i>H</i>. The results confirm temperature as the dominant factor influencing both responses. At the optimal setting (α = 65°, T = 150&#xa0;°C, D = 10&#xa0;mm, t<sub>z</sub> = 0.5&#xa0;mm), the average forming force decreased by 31.67%, while fracture height increased by 34.29% compared to the baseline condition. Experimental validation of the optimized Grey Relational Grade (GRG = 1.0) demonstrated excellent agreement with the predicted values, confirming the robustness of the optimization framework. Beyond process improvement, the proposed methodology reduces tool and machine demands, lowers energy consumption, and broadens the formability limits of aluminum alloys, offering tangible benefits for sustainable and cost-effective manufacturing.</p>

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Parametric study and multi-objective optimization in heat-assisted single point incremental forming of AA1050 aluminum alloy using experimental design methods

  • 期刊论文

  • 发表日期：

    2025年11月7日

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  • Trung-Kien Hoang,
  • Thi-Bich Mac,
  • The-Thanh Luyen,
  • Duc-Toan Nguyen

摘要

Experimental research plays a central role in advancing modern manufacturing by validating theoretical models and guiding the development of improved forming processes. This study examines the influence of critical process parameters on forming force (FF) and fracture height (H) in heat-assisted single point incremental forming (HA-SPIF) of AA1050 aluminum alloy sheets. A novel uniform heating method was implemented to stabilize thermal conditions and improve material deformation behavior. The effects of wall angle, forming temperature, tool diameter, and vertical step size were systematically analyzed using a Taguchi L9 design of experiments coupled with analysis of variance (ANOVA). Multi-objective optimization was then performed through Grey Relational Analysis (GRA), targeting the simultaneous minimization of FF and maximization of H. The results confirm temperature as the dominant factor influencing both responses. At the optimal setting (α = 65°, T = 150 °C, D = 10 mm, tz = 0.5 mm), the average forming force decreased by 31.67%, while fracture height increased by 34.29% compared to the baseline condition. Experimental validation of the optimized Grey Relational Grade (GRG = 1.0) demonstrated excellent agreement with the predicted values, confirming the robustness of the optimization framework. Beyond process improvement, the proposed methodology reduces tool and machine demands, lowers energy consumption, and broadens the formability limits of aluminum alloys, offering tangible benefits for sustainable and cost-effective manufacturing.