Effect Analysis of Process Parameters on Geometric Dimensions during Belt-Heated Incremental Sheet Forming of AA2024 Aluminum Alloy
, Zhiguo An 2,*, Han Lin 3, Pengfei Sun 2, Zhong Ren 4, Zhengyang Qiao 5, Yuhang Zhang 1 and Youdong Jia 1
Round 1
Reviewer 1 Report
Comments and Suggestions for AuthorsThis work finds the influence law for geometric errors with varying process parameters. It examines the deformed section's micromorphology and how belt-heated incremental sheet-forming process factors affect it. Additionally, XRD measures region-section dislocation density and deformation. A dislocation density change law is given for different process parameters. The results obtained in the manuscript are of technological importance and the paper could be published after few supplements.
Comments for author File: 
Comments.pdf
Author Response
Question1: Please provide complete information of instrumentation (XRD and SEM) details in the manuscript.
Response: The reviewer’s comment is very instructive. The instrumentation model for XRD and SEM has been added in the revised manuscript.
Question2: In figure7, the scale is not visible. Please draw the scale in all the images.
Response: The reviewer’s comment is very instructive. The scale of Figure 7 has been revised.
Question3: Please add a few sentences on future directions of this work.
Response: The reviewer’s comment is very instructive. The future direction of this work has been added.
Question4: Please cite more references from 2023. No one article from 2023 was cited.
Response: The reviewer’s comment is very instructive. Some references from the last 5 years are added in the revised manuscript.
Reviewer 2 Report
Comments and Suggestions for AuthorsThis manuscript presents a well-structured approach to analyzing the effect of process parameters on geometric accuracy in belt-heated incremental sheet forming (ISHF) of AA2024 aluminum alloy. The identification of tool diameter and step down as the primary factors influencing geometric dimensions at specific center distances is a valuable contribution. However, some aspects require clarification and additional information before publication as follows;
- The introduction is weak. The author should give an adequate review of the last achievements in the research area with adequate references. More importantly, the authors should clarify the novelty of this work.
- Limited details on macro and micro experiments: The description of the experiments (e.g., sample size, specific measurement techniques) could be more detailed. Please in the revised version of the manuscript provide more details on the macro and micro experiments conducted.
- Lack of quantitative data: While the influence of parameters is discussed, including specific data on the changes in geometric dimensions and dislocation density would strengthen the conclusions. The authors should add more details and include quantitative data on the changes in geometric dimensions and dislocation density in the revised version of the manuscript.
- Limited discussion on tearing ridge formation: While the tearing ridge is mentioned as an issue with a 12mm tool diameter, further explanation of its impact and potential mitigation strategies would be beneficial. The authors should expand the discussion on tearing ridge formation, its impact, and mitigation strategies.
- Ignoring potential influence of feed rate: Completely disregarding the influence of feed rate on geometric accuracy might be too hasty. Including data or justification for this exclusion would strengthen the conclusion. It will be great if the authors consider including data or justification for disregarding the influence of feed rate.
- Consider mentioning the limitations of the study (e.g., specific forming geometry used).
- Briefly discuss the potential for applying these findings to other materials or forming processes.
Minors issue.
1- The inset of Figure 5, Figure 6 and Figure 7 are hardly seen, please in the revised present these Figures in more clear way.
2- I think Figures 3 and 4 can be combined in one Figure
3- The authors should add more details for these conditions “A high-temperature chain oil of 600℃ was used to ensure the surface quality of materials in this work” why 600 C?
4- If possible, can the authors add EDX analysis and element distribution
Author Response
Question1: The introduction is weak. The author should give an adequate review of the last achievements in the research area with adequate references. More importantly, the authors should clarify the novelty of this work.
Response: The reviewer’s comment is very instructive. The introduction has been revised.
Question2: Limited details on macro and micro experiments: The description of the experiments (e.g., sample size, specific measurement techniques) could be more detailed. Please in the revised version of the manuscript provide more details on the macro and micro experiments conducted.
Response: The reviewer’s comment is very instructive. The macro and micro experiments have been revised.
Question3: Lack of quantitative data: While the influence of parameters is discussed, including specific data on the changes in geometric dimensions and dislocation density would strengthen the conclusions. The authors should add more details and include quantitative data on the changes in geometric dimensions and dislocation density in the revised version of the manuscript.
Response: The reviewer’s comment is very instructive. The relation between the geometric dimension and the dislocation density has been analyzed.
Question4: Limited discussion on tearing ridge formation: While the tearing ridge is mentioned as an issue with a 12mm tool diameter, further explanation of its impact and potential mitigation strategies would be beneficial. The authors should expand the discussion on tearing ridge formation, its impact, and mitigation strategies.
Response: The reviewer’s comment is very instructive. The tearing ridge, which leads to the fracture trend, is caused by the tool of 12mm diameter. Therefore, the tool of 12mm diameter should be avoided in the forming process, which has been illustrated in the revised manuscript.
Question5: Ignoring potential influence of feed rate: Completely disregarding the influence of feed rate on geometric accuracy might be too hasty. Including data or justification for this exclusion would strengthen the conclusion. It will be great if the authors consider including data or justification for disregarding the influence of feed rate.
Response: The reviewer’s comment is very instructive. The effect of the feed rate is slight according to the macro and micro results, and then the effect of the feed rate on the geometric accuracy is ignored in the square cone forming process.
Question6: Consider mentioning the limitations of the study (e.g., specific forming geometry used).
Response: The reviewer’s comment is very instructive. The square cone is adopted to analyze the effect of process parameters on the geometric accuracy. Therefore, the specific geometry has been described in the revised manuscript.
Question7: Briefly discuss the potential for applying these findings to other materials or forming processes.
Response: The reviewer’s comment is very instructive. A briefly discuss has been added in conclusions.
Question8: The inset of Figure 5, Figure 6 and Figure 7 are hardly seen, please in the revised present these Figures in more clear way.
Response: The reviewer’s comment is very instructive. These figures have been revised.
Question9: I think Figures 3 and 4 can be combined in one Figure
Response: The reviewer’s comment is very instructive. Figures 3 and 4 have been combined in the revised manuscript.
Question10: The authors should add more details for these conditions “A high-temperature chain oil of 600℃ was used to ensure the surface quality of materials in this work” why 600 C?
Response: The reviewer’s comment is very instructive. The lubricating property of 600℃ high-temperature oil can be ensured since 600℃ is far greater than 180℃.
Question11: If possible, can the authors add EDX analysis and element distribution.
Response: The reviewer’s comment is very instructive. The EDX analysis can be implemented in the following study.
Reviewer 3 Report
Comments and Suggestions for AuthorsThe article under consideration analysis effect of process parameters on geometric dimensions of aluminum parts (AA2024 alloy) produced during belt-heated incremental sheet forming. Although the subject matter is interesting especially from industry perspectives, the manuscript requires several corrections and clarifications, namely:
1. Introduction: only 30% of bibliographic items come from the last 5 years (2024-2020, including 6 references from 2020 and one reference each from 2022 and 2023) the other references come from 2018-2005. It seems to me advisable to supplement the literature review with the latest publications, especially those relating to the incremental sheet forming of aluminum.
2. The introduction should clearly state what distinguishes this work from the previous research; what new elements the work brings to research
3. Figs 4 and 5: justify why this area was selected for analysis
4. Figs 5 and 6: the quality of the figures should be improved - it is difficult to distinguish colors; what does “axial absolute value” mean.
5. How many parts in each experimental group were measured to determine the impact of various process parameters on geometric errors
Author Response
Question1: Introduction: only 30% of bibliographic items come from the last 5 years (2024-2020, including 6 references from 2020 and one reference each from 2022 and 2023) the other references come from 2018-2005. It seems to me advisable to supplement the literature review with the latest publications, especially those relating to the incremental sheet forming of aluminum.
Response: The reviewer’s comment is very instructive. Some references from the last 5 years are added in the revised manuscript.
Question2: The introduction should clearly state what distinguishes this work from the previous research; what new elements the work brings to research.
Response: The reviewer’s comment is very instructive. The introduction section of the revised manuscript has been modified.
Question3: Figs 4 and 5: justify why this area was selected for analysis.
Response: The reviewer’s comment is very instructive. The inclined wall is the major deformed region, as shown in Figure 3b. Therefore, the deformed region can clearly describe material microscopic characteristics.
Question4: Figs 5 and 6: the quality of the figures should be improved - it is difficult to distinguish colors; what does “axial absolute value” mean.
Response: The reviewer’s comment is very instructive. The quality of the two figures has been revised, and the axial absolute value is the axial difference between the design contour and the actual contour.
Question5: How many parts in each experimental group were measured to determine the impact of various process parameters on geometric errors.
Response: The reviewer’s comment is very instructive. The three parts of each group are adopted to determine the geometric error of each group.
Round 2
Reviewer 2 Report
Comments and Suggestions for AuthorsThe revised version of the manuscript is improved a lot and the current version can be accepted in the present form.
