Application of Incremental Forming process for high customised medical product manufacturing
TL;DR: In this article, a particular application is carried out taking into account the development of an innovative technique to produce a customised ankle support, exalting the role that this technology may play when single complex product has to be manufactured.
About: This article is published in Journal of Materials Processing Technology.The article was published on 2005-05-15. It has received 269 citations till now. The article focuses on the topics: Incremental sheet forming & Stamping.
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TL;DR: In this article, a wide recognition of the research efforts in this field is presented, taking into account some general considerations on the difference sources of shape and dimensional errors, as well as the influence of the most relevant parameters.
228 citations
TL;DR: In this paper, the authors presented an innovative and viable method to test the thinning limits of sheet metals in Negative Incremental Forming along with verification of the Cosine's law of thickness distribution.
Abstract: Single Point Incremental Forming (SPIF) is an emerging sheet-metal-forming technology, capable of manufacturing complex parts at low cost for small to medium-batch production. The present paper is focused on presenting an innovative and viable method to test the thinning limits of sheet metals in Negative Incremental Forming along with verification of the Cosine's law of thickness distribution. The Cosine's law was verified by comparing the experimentally measured thicknesses of incrementally formed parts with those predicted by the law. To test the thinning limit of a sheet metal, the idea is based on the forming of an axi-symmetric part varying its slope with depth corresponding to varying thinning. An arc of a circle was selected as generatrix to model such an axi-symmetric part. Based on the Cosine's law, mathematical expressions were derived to predict the thickness distribution along the depth of the part and the thinning limit of the sheet-metal. The Aluminum sheet metal was used as an experimental material. In order to test its thinning limit, the axi-symmetric part, modeled with a generatrix arc, was formed incrementally until it cracked. Thickness of the fractured part was measured at various points along its depth and compared with that predicted by the Cosine's law. The maximum thinning at a point, at which thickness followed the Cosine's law, was called the thinning limit of the sheet metal. In order to obtain accurate results, four such parts having the same generatrix design were formed. Based on these results, several axi-symmetric and asymmetric parts were formed at fixed slopes. It was found that the thinning limits obtained from the parts formed at fixed slopes were a little lower than those obtained from the parts modeled with the same generatrix design. As conclusion, a strategy to test the lowest possible thinning limits of sheet metals has been proposed. The proposed method is capable to test the thinning limits of sheet metals at reduced processing time and cost.
212 citations
TL;DR: In this article, a new method is proposed for hot incremental forming, which makes use of electric current for heating hard-to-form sheet metals at the tool-sheet interface in order to fully utilize the formability of these materials.
Abstract: In the current work, a new method is proposed for hot incremental forming. The method is based on simple tooling and is easy to employ. It makes use of electric current for heating hard-to-form sheet metals at the tool–sheet interface in order to fully utilize the formability of these materials. The potential effect of processing parameters, namely current, tool size, feed rate and step size, on the formability are investigated using AZ31 magnesium. In addition to this, the shape distortion of TiAl2Mn1.5 titanium workpiece after hot forming has also been addressed herein. Experimental results demonstrate that this technique is feasible and easy to control.
179 citations
TL;DR: In this article, the state-of-the-art of single point incremental forming (SPIF) is presented, where a flat sheet is incrementally deformed into a desired shape by the action of a tool that follows a defined toolpath conforming to the final part geometry.
177 citations
TL;DR: An overview of the body of knowledge with respect to Single Point Incremental Forming is provided to provide an up-to-date state-of-the-art review with corresponding conclusions on scientific progress and outlook on expected further developments.
Abstract: Incremental sheet metal forming in general and Single Point Incremental Forming (SPIF) specifically have gone through a period of intensive development with growing attention from research institutes worldwide. The result of these efforts is significant progress in the understanding of the underlying forming mechanisms and opportunities as well as limitations associated with this category of flexible forming processes. Furthermore, creative process design efforts have enhanced the process capabilities and process planning methods. Also, simulation capabilities have evolved substantially. This review paper aims to provide an overview of the body of knowledge with respect to Single Point Incremental Forming. Without claiming to be exhaustive, each section aims for an up-to-date state-of-the-art review with corresponding conclusions on scientific progress and outlook on expected further developments.
161 citations
References
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TL;DR: Specific issues addressed include characterization of geometric models and related surface representations, segmentation and surface fitting for simple and free-form shapes, multiple view combination and creating consistent and accurate B-rep models.
Abstract: In many areas of industry, it is desirable to create geometric models of existing objects for which no such model is available. This paper reviews the process of reverse engineering of shapes. After identifying the purpose of reverse engineering and the main application areas, the most important algorithmic steps are outlined and various reconstruction strategies are presented. Pros and cons of various data acquisition techniques are described with related problems of boundary representation model construction. Specific issues addressed include characterization of geometric models and related surface representations, segmentation and surface fitting for simple and free-form shapes, multiple view combination and creating consistent and accurate B-rep models. The limitations of currently known solutions are also described, and we point out areas in which further work is required before reverse engineering of shape becomes a practical, widely-available engineering tool.
1,243 citations
TL;DR: In this paper, the idea of incremental forming technique has been investigated for production of sheet metal components, and the formability of an aluminum sheet under various forming conditions was assessed and difficult-to-form shapes were produced with the technique.
243 citations
"Application of Incremental Forming ..." refers background in this paper
...In fact, due to the very ow set-up cost, the use of this technology may be strategic hen industries require small batch or single products [1,2]....
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TL;DR: In this paper, an incremental sheet metal forming process controlled three dimensionally by a computer has been accomplished, where a small local region of a sheet blank deforms incrementally by moving a hemispherical head tool over an arbitrary surface.
225 citations
"Application of Incremental Forming ..." refers background in this paper
...This aspect results in a strong formability increasing [5–8]: the material FLD0 becomes very high if compared to the one shown in traditional stamping processes, even two or three times....
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TL;DR: In this article, a forming tool containing a freely rotating ball was developed and used to characterize the formability of fully annealed Al 1050 sheet in incremental forming, where various strain paths were applied to the sheet by imposing different tool paths and the major and minor strains of deformed grids around cracks were measured.
212 citations
"Application of Incremental Forming ..." refers background in this paper
...This aspect results in a strong formability increasing [5–8]: the material FLD0 becomes very high if compared to the one shown in traditional stamping processes, even two or three times....
[...]
TL;DR: In this article, an integrated numerical/experimental procedure is proposed in order to limit the shape defects between the obtained geometry and the desired one, with the aim to quantify the geometrical discrepancies.
174 citations
"Application of Incremental Forming ..." refers background in this paper
...In this contest, a previous work of the authors has shown hat it is possible to improve the geometrical accuracy of the nal product, reducing the discrepancies up to the 70%, with proper selection of these parameters [4]....
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...More in detail, in this kind of application but, in general, in all the operations in which Incremental Forming processes are involved, one of the main drawbacks is represented by the discrepancies between the desired shape and the obtained one [4]....
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