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Plastic deformation forming with metal pipe blanks by contact blast loading inside pipes is an interesting moldless forming technique, also a complex and error-prone process. Some advantages are very characteristic of this forming technique such as no cost of mold, tooling and low energy consumption, no complicated control equipment compared to other forming techniques such as casting, rolling, tube hydrostatic forming, bending – welding. Up to now, the calculation and design of this forming technique mainly use some existing reference empirical formulas, so the experimental results are only suitable in the range of small pipe diameters, and still there are significant deviations for larger pipe diameters. In order to increase the predictability and accuracy of forming process by contact blast loading inside large pipes, this paper presents a study on the influence of the mass of highly explosive material – TNT to the forming ability of large steel pipes from API-5LX-42 mild steel materials by modern 3D numerical simulation – using Abaqus/Cae software. Four output criteria with maximum values are used to evaluate the efficiency of this forming process, including maximum diameter of the blast zone (Dmax£2D0), Von Mises stress (Smax£UTS), Hoop plastic strain component (PE22max£1), and Pipe wall thinning rate (eT-max£60 %). The results of this research on the plastic deformation forming process using numerical simulation can be used for the next experimental step to evaluate the difference between simulation and experiment, as well as use this data in the calculation and design of pipe products with circular or square cross-sections to save both time and money of trial and error before application in actual manufacturing

This study investigates toolpath strategies of multi-pass incremental sheet forming (MSPIF) including a combination of an IN (I) pass where the tool moves inwards and downwards and an OUT (O) pass where the tool moves outward and upward. MSPIF processes (III, IIO, IOI and IOO) were investigated to form cone and dome shapes using experimental testing and finite element (FE) simulation. It was found that any IN pass after the initial IN pass, produced stepped features due to Rigid Body Translation (RBT) of the formed part, with the magnitude of the step being dependent on the both the quantity and position of the IN passes. The IOO strategy was more effective in producing a flat bottom cup (no stepped features), but due to the succession of OUT passes used, sheet thinning occurred near the centre of the formed part. A 4-stage IOOO strategy successfully increased the final maximum draw angle by 23% relative to the maximum wall angle of a single pass. The results have shown that the MSPIF approach can be used as an effective means to improve the formability in incremental sheet forming.

The development of plastic product prototype by incremental sheet forming (ISF) has attracted extensive attention. Forming polyvinyl chloride (PVC) sheet into parts by ISF has a wide application prospect in many industrial fields. However, torsion is a problem that needs to be solved. In this paper, some truncated pyramids were formed by different feed speeds and tool paths with a certain spindle speed of the tool. Torsion angle of central line and accuracy of each formed part were measured. In addition, numerical simulation was also used to get the influence of tool path on the torsion of PVC parts. The results show that PVC part appears torsion around the central axis when it was formed by the unidirectional direction tool path, and torsion increases and accuracy reduces with increment of feed speed of the tool. Otherwise, the alternating bidirectional direction tool path can effectively eliminate the torsion of PVC part.

This paper presents a detailed literature review on the current research of incremental sheet forming relating to deformation mechanism, modelling techniques, forming force prediction and process investigations. First, a review of the fundamental deformation mechanism and formability in incremental sheet forming (ISF) is provided. Subsequently, the modelling techniques for ISF are reviewed and categorised into two approaches: analytical modelling and finite element modelling. Special interest is given to a critical review regarding the forming forces analysis and prediction during the process. Then, previous publications related to geometric accuracy, surface finish and forming efficiency in ISF are reviewed. Finally, several potential hybrid incremental sheet-forming strategies are discussed. This leads to a statement of conclusion which may act as an inspiration and reference for the researcher.

Incremental sheet forming technology has great potential for forming thin-walled parts. However, the excessive thinning rate and uneven thickness distribution seriously affect the performance of forming. To reduce the sheet thickness reduction rate during the incremental forming process, hydraulically supported incremental forming technology is adopted, the thickness reduction rate of parts with different pressures, sheet thicknesses, and sizes was experimentally investigated and optimized by using Taguchi’s method. The results show that in the designed experimental scheme, the most significant elements affecting the thickness reduction rate are the forming angle and hydraulic pressure; the optimum thickness reduction rate is obtained by selecting the appropriate hydraulic pressure, lower forming angle, and larger sheet thickness. In incremental forming, this helps to enhance the thickness uniformity of parts, the quality, and the formability of the form.

Incremental sheet forming (ISF) is a relatively new flexible forming process. ISF has excellent adaptability to conventional milling machines and requires minimum use of complex tooling, dies and forming press, which makes the process cost-effective and easy to automate for various applications. In the past two decades, extensive research on ISF has resulted in significant advances being made in fundamental understanding and development of new processing and tooling solutions. However, ISF has yet to be fully implemented to mainstream high-value manufacturing industries due to a number of technical challenges, all of which are directly related to ISF process parameters. This paper aims to provide a detailed review of the current state-of-the-art of ISF processes in terms of its technological capabilities and specific limitations with discussions on the ISF process parameters and their effects on ISF processes. Particular attention is given to the ISF process parameters on the formability, deformation and failure mechanics, springback and accuracy and surface roughness. This leads to a number of recommendations that are considered essential for future research effort.

The tube hydroforming technology is a rapid-forming technique in multi-way tube integrated and lightweight manufacturing. The forming performance of the multi-way tube under this technology was comprehensively analyzed and summarized in this paper. Firstly, the influencing factors, such as axial feed loading path and internal pressure, forming friction, and die transition fillet, in the process of multi-way tube forming were analyzed and summarized. Secondly, the optimization method of the multi-way tube forming performance in hydroforming was analyzed. Finally, the reduction of hydraulic expansion costs and the development of new hydroforming technologies were expounded.

Fibre metal laminates, hybrid composite materials built up from interlaced layers of thin metals and fibre reinforced adhesives, are future-proof materials used in the production of passenger aircraft, yachts, sailplanes, racing cars, and sports equipment. The most commercially available fibre–metal laminates are carbon reinforced aluminium laminates, aramid reinforced aluminium laminates, and glass reinforced aluminium laminates. This review emphasises the developing technologies for forming hybrid metal–polymer composites (HMPC). New advances and future possibilities in the forming technology for this group of materials is discussed. A brief classification of the currently available types of FMLs and details of their methods of fabrication are also presented. Particular emphasis was placed on the methods of shaping FMLs using plastic working techniques, i.e., incremental sheet forming, shot peening forming, press brake bending, electro-magnetic forming, hydroforming, and stamping. Current progress and the future directions of research on HMPCs are summarised and presented.

This study investigates the influence of two different forming methods, dry pressing and plastic forming, on the physical properties of traditional porcelain doped with waste glass. Samples were prepared from an identical composition consisting of 50 wt.% kaolinitic clay, 25 wt.% quartz, and 25 wt.% feldspar, partially or fully replaced by waste glass in amounts ranging from 5 to 25 wt.%. While dry pressing was performed using a uniaxial load of 20 MPa, plastic forming involved shaping plastic bodies prepared with appropriate water content. The samples were subjected to stepwise heating up to 1100 °C, with measurements focused on bulk and matrix density, porosity, and volumetric shrinkage at each stage. The results reveal notable differences between the two forming methods, particularly in sintering behavior and shrinkage development. Uniaxially pressed samples exhibit more efficient shrinkage and densification compared to plastically shaped ones. These findings highlight the impact of forming techniques on the evolution of physical properties in porcelain ceramics containing recycled waste glass.

Incremental sheet forming of titanium and its alloys has a significant role in modern manufacturing techniques because it allows for the production of high-quality products with complex shapes at low production costs. Stamping processes are a major contributor to plastic working techniques in industries such as automotive, aerospace and medicine. This article reviews the development of the single-point incremental forming (SPIF) technique in titanium and its alloys. Problems of a tribological and microstructural nature that make it difficult to obtain components with the desired geometric and shape accuracy are discussed. Great emphasis is placed on current trends in SPIF of difficult-to-form α-, α + β- and β-type titanium alloys. Potential uses of SPIF for forming products in various industries are also indicated, with a particular focus on medical applications. The conclusions of the review provide a structured guideline for scientists and practitioners working on incremental forming of titanium and titanium alloy sheets. One of the ways to increase the formability and minimize the springback of titanium alloys is to treat them at elevated temperatures. The main approaches developed for introducing temperature into a workpiece are friction heating, electrical heating and laser heating. The selection of an appropriate lubricant is a key aspect of the forming process of titanium and its alloys, which exhibit unfavorable tribological properties such as high adhesion and a tendency to adhesive wear. A review of the literature showed that there are insufficient investigations into the synergistic effect of rotational speed and tool rotation direction on the surface roughness of workpieces.