Vibration Analysis of Forming Tool and Thin Sheet Metal in Robot-Based Single Point Incremental Sheet Forming

Abstract

Robot-based incremental sheet forming is an approach in producing sheet metal products with innovative and flexibility of the robot technologies. Since the tool condition monitoring plays a vital role in process performance, a robust detection system with reliable pattern recognition on tool wear and product quality need to be developed. This study demonstrates the evaluation of vibration signal using accelerator sensor to correlate with tool wear of forming tool and surface roughness of workpiece in robot-based incremental sheet forming. The experiments were conducted by evaluating the vibration signal generated by the forming tool made of AISI D2 on workpiece of SUS 316. Pattern recognition was gathered to identify and categorize the characterization of tool wear by two cluster; tool in good condition and worn out. The results indicate that the frictional between surface of forming tool and workpiece is directly proportional to tool wear. The increasing of surface roughness on the workpiece can also be seen noticeably with the increasing of vibration on the forming process due to tool wear. This proving that vibration signal can provide the tool wear identification for this ISF process. The development of efficient pattern recognition is important to identify the tool condition and forming tool performance in products quality consistently.