Evidence map›Paper›PMID 41998085›Full record

ArticleScientific reports2026

Elucidating formability limits in warm incremental sheet forming of AZ61 magnesium alloy using integrated grey relational and data-driven analysis.

Anjali R Magdum, Rohit A Magdum, Pandivelan Chinnaiyan, Pankaj Patil, Amar Khot, Obinna Onyebuchi Barah

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Article in Scientific reports, 2026. The graph could read no effect estimate from its abstract, so it casts no vote on the map. Not yet cited in PubMed.

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6 authors.

Anjali R MagdumDepartment of Electronics and Computer Engineering, Sharad Institute of Technology College of Engineering, Yadrav, Maharashtra, 416121, India.
Rohit A MagdumDepartment of Mechanical Engineering, Kasegaon Education Society's, Rajarambapu Institute of Technology, Affiliated to Shivaji University, Sakharale, MS, 415414, India. rmagdum73@gmail.com.
Pandivelan ChinnaiyanSchool of Mechanical Engineering, VIT, Vellore, 632014, India.
Pankaj PatilDepartment of Mechatronics Engineering, Sharad Institute of Technology college of engineering, Yadrav, Maharashtra, 416121, India.
Amar KhotDepartment of Mechanical Engineering, Sharad Institute of Technology college of engineering, Yadrav, Maharashtra, 416121, India.
Obinna Onyebuchi BarahDepartment of Mechanical Engineering, School of Engineering and Applied Sciences, Kampala International University, Western Campus, Ishaka-Bushenyi, P.O. Box 20,000, Kampala, Uganda. obinna.barah@kiu.ac.ug.

Funding

No grant is acknowledged in the PubMed record.

6 · The paper itself

Abstract

The growing demand for lightweight structural components in the automotive and aerospace sectors has intensified interest in magnesium alloys; however, their limited formability at room temperature continues to restrict widespread industrial adoption. In this study, the formability and surface quality of AZ61 magnesium alloy during warm incremental sheet forming (ISF) are systematically investigated. A straight-groove forming test was conducted using a Taguchi L27 experimental design to evaluate the effects of key process parameters. To simultaneously optimize formability and surface roughness, Grey Relational Analysis (GRA) was employed. Analysis of Variance (ANOVA) of the GRA results revealed that step depth was the most influential parameter, contributing 70.12% to the total variance, followed by spindle speed with a contribution of 12.97%, while tool diameter and feed rate exhibited comparatively minor effects. The optimal parameter combination, 8 mm tool diameter, 700 rpm spindle speed, 0.3 mm step depth, and 500 mm/min feed rate, resulted in enhanced formability and improved surface quality. Forming Limit Diagram (FLD) analysis confirmed an expansion of the safe deformation zone under optimized conditions. Scanning Electron Microscopy (SEM) observations indicated a predominantly ductile fracture mode characterized by deep dimples and fibrous tearing. Furthermore, a Random Forest-based machine learning model corroborated the ANOVA findings, providing additional validation and trend confirmation for the identified parameter influences. The integrated experimental and data-driven framework presented in this work supports the development of intelligent and optimized warm ISF processes for magnesium alloys.

Indexed as

AZ61 magnesium alloyFormabilityForming limit diagramGrey relational analysisOptimizationSurface roughnessWarm incremental sheet forming

Identifiers

PMID41998085
PMCPMC13246949

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