Process Parameters Optimization of the Explosive-Welded Al/Cu Bimetal in the Incremental Sheet Metal Forming Process

Incremental sheet metal forming process is used to form three-dimensional parts without using die and specific forming tool. In this study, the effects of process parameters are experimentally and mathematically investigated on the incremental forming of explosive-welded Al/Cu bimetals. The mathematical analysis was used for designing the experiments and optimization of the process. Tool diameter, vertical step, tool path and layer arrangement (contacted layer with the tool) are input parameters, and surface roughness, maximum thickness variation (the maximum difference between initial thickness and formed sample thickness), forming time (the required time to forming the sheet) and forming forces (the required forces to form the sheets) are the outputs. The results of the mathematical model show that the presented mathematical method could provide a suitable description of the operation and corresponds with the experimental results. Finally, the best parameters were presented to obtain the optimum outputs.