Explore the vast range of titles available.

Incremental sheet forming (ISF) is a recently developed manufacturing technique. In ISF, forming is done by applying deformation force through the motion of Numerically controlled (NC) single point forming tool on the clamped sheet metal blank. Single Point Incremental sheet forming (SPISF) is also known as a die-less forming process because no die is required to fabricate any component by using this process. Now a day it is widely accepted for rapid manufacturing of sheet metal components. The formability of SPISF process improves by adding some intermediate stages into it, which is known as Multi-stage SPISF (MSPISF) process. However during forming in MSPISF process because of intermediate stages stepped features are generated. This paper investigates the generation of stepped features with simulation and experimental results. An effective MSPISF strategy is proposed to remove or eliminate this generated undesirable stepped features.

This study focuses on the influence of modifications of the material and geometry of the forming tool on the process of single-point incremental forming of titanium sheets CP-Ti Gr 2 and Ti-6Al-4V. The aim of the research was to analyze the influence of variants of the tool material and modifications of the geometry in the form of grooves with different arrangements on the forming process and the quality of the obtained drawpieces. Additionally, the influence of lubricant type and the heating method on the efficiency of the process was examined. Forming CP-Ti Gr 2 sheets using lubrication grooves on the tools did not contribute to the surface roughness and deformation improvement of the drawpieces. The most favorable results for CP-Ti Gr 2 sheet were obtained using a tool made of Al2O3 ceramics reinforced with SiC whiskers, warming with heating oil and lubrication with rape-seed oil. In the case of Ti-6Al-4V sheets, it was found that the uncoated carbide tool allowed for the greatest deformation of the drawpiece compared to the tools coated with different coatings and whisker-reinforced ceramics. The use of coatings did not have a positive effect on the process in terms of the coefficient of friction, tool wear and the drawpiece deformation. The conducted studies allow for a better understanding of the relationship between tool modification and the efficiency of the single-point forming process of titanium sheets and the quality of the obtained drawpieces.

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.

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.

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.

The employment of a green manufacturing process can directly save energy and materials in industrial sectors. Single Point Incremental Forming (SPIF) is an agile and flexible method of fabricating sheet material components and exempts the use of dedicated die-sets which further makes it a choice of green manufacturing. Furthermore, the customized components can be easily fabricated by SPIF economically. The surface quality of fabricated parts can greatly decide the suitability and sustainability of the process in various applications. This work investigates the impact of significant process factors on the roughness of the parts during the SPIF process. The average roughness has been considered to determine the surface quality. The increment in the value of wall angle and step size resulted in the increment in Ra value of formed components drastically. It was also observed that as the forming angle was raised from a lower level (60°) to a higher level (68°), the Ra value was found to increase significantly.

The article presents the results of the analysis of the influence of incremental sheet forming process parameters on surface roughness measured on both sides of conical drawpieces made from pure titanium Grade 2 sheets. The experimental plan was created on the basis of a central composite design. The study assumed the variability of feed rate, spindle speed, and incremental step size in the following range: 500–2000 mm/min, 0–600 rpm, and 0.1–0.5 mm, respectively. Two strategies differing in the direction of the tool rotation in relation to the feed direction were also analysed. Analysis of variance is performed to understand the adequacy of the proposed model and the influence of the input parameters on the specific roughness parameter. The sensitivity of the process parameter on the selected surface roughness parameters was assessed using artificial neural networks. It was found that the change in the surface roughness of the inner surface of the drawpiece is not related to the change of surface roughness of the outer side. The morphology of the outer surface of the draw pieces was uniform with a much greater profile height than the inner surface that had interacted with the tool. Taking into account the outer surface of the drawpiece, the direction of tool rotation is also most closely correlated with the parameters Sa, Sz, and Sku. Step size and feed rate provide the highest information capacity in relation to skewness and kurtosis of the inner surface of the drawpiece.

Lightweight materials, such as titanium alloys, magnesium alloys, and aluminium alloys, are characterised by unusual combinations of high strength, corrosion resistance, and low weight. However, some of the grades of these alloys exhibit poor formability at room temperature, which limits their application in sheet metal-forming processes. Lightweight materials are used extensively in the automobile and aerospace industries, leading to increasing demands for advanced forming technologies. This article presents a brief overview of state-of-the-art methods of incremental sheet forming (ISF) for lightweight materials with a special emphasis on the research published in 2015–2021. First, a review of the incremental forming method is provided. Next, the effect of the process conditions (i.e., forming tool, forming path, forming parameters) on the surface finish of drawpieces, geometric accuracy, and process formability of the sheet metals in conventional ISF and thermally-assisted ISF variants are considered. Special attention is given to a review of the effects of contact conditions between the tool and sheet metal on material deformation. The previous publications related to emerging incremental forming technologies, i.e., laser-assisted ISF, water jet ISF, electrically-assisted ISF and ultrasonic-assisted ISF, are also reviewed. The paper seeks to guide and inspire researchers by identifying the current development trends of the valuable contributions made in the field of SPIF of lightweight metallic materials.

Sheet metal forming (SMF) is one of the most popular technologies for obtaining finished products in almost every sector of industrial production, especially in the aircraft, automotive, food and home appliance industries. Parallel to the development of new forming techniques, numerical and empirical approaches are being developed to improve existing and develop new methods of sheet metal forming. Many innovative numerical algorithms, experimental methods and theoretical contributions have recently been proposed for SMF by researchers and business research centers. These methods are mainly focused on the improvement of the formability of materials, production of complex-shaped parts with good surface quality, speeding up of the production cycle, reduction in the number of operations and the environmental performance of manufacturing. This study is intended to summarize recent development trends in both the numerical and experimental fields of conventional deep-drawing, spinning, flexible-die forming, electromagnetic forming and computer-controlled forming methods like incremental sheet forming. The review is limited to the considerable changes that have occurred in the SMF sector in the last decade, with special attention given to the 2015–2020 period. The progress observed in the last decade in the area of SMF mainly concerns the development nonconventional methods of forming difficult-to-form lightweight materials for automotive and aircraft applications. In evaluating the ecological convenience of SMF processes, the tribological aspects have also become the subject of great attention.

Single point incremental forming (SPIF) is becoming more and more widely used in the metal industry due to its high production flexibility and the possibility of obtaining larger material deformations than during conventional sheet metal forming processes. This paper presents the results of the numerical modeling of friction stir rotation-assisted SPIF of commercially pure 0.4 mm-thick titanium sheets. The aim of this research was to build a reliable finite element-based thermo-mechanical model of the warm forming process of titanium sheets. Finite element-based simulations were conducted in Abaqus/Explicit software (version 2019). The formability of sheet metal when forming conical cones with a slope angle of 45° was analyzed. The numerical model assumes complex thermal interactions between the forming tool, the sheet metal and the surroundings. The heat generation capability was used to heat generation caused by frictional sliding. Mesh sensitivity analysis showed that a 1 mm mesh provides the best agreement with the experimental results of total forming force (prediction error 3%). It was observed that the higher the size of finite elements (2 mm and 4 mm), the greater the fluctuation of the total forming force. The maximum temperature recorded in the contact zone using the FLIR T400 infrared camera was 157 °C, while the FE-based model predicted this value with an error of 1.3%. The thinning detected by measuring the drawpiece with the ARGUS non-contact strain measuring system and predicted by the FEM model showed a uniform thickness in the drawpiece wall zone. The FE-based model overestimated the minimum and maximum wall thicknesses by 3.7 and 5.9%, respectively.