Manufacture of Accurate Titanium Cranio-Facial Implants with High Forming Angle Using Single Point Incremental Forming

2013 ◽  
Vol 549 ◽  
pp. 223-230 ◽  
Author(s):  
Joost R. Duflou ◽  
Amar Kumar Behera ◽  
Hans Vanhove ◽  
Liciane S. Bertol
Keyword(s):  
Incremental Forming ◽  
Single Point ◽  
Design Feature ◽  
Feature Analysis ◽  
Medical Applications ◽  
Single Point Incremental Forming ◽  
Wall Angle ◽  
Titanium Grade ◽  
Intermediate Part ◽  
Forming Angle

One of the key application areas of Single Point Incremental Forming is in the manufacture of parts for bio-medical applications. This paper discusses the challenges associated with the manufacture of cranio-facial implants with extreme forming angles using medical grade titanium sheets. While on one hand, the failure wall angle is an issue of concern, the parts also need to be manufactured with accuracy at the edges where the implants fit into the human body. Systematic steps taken to overcome these challenges, using intelligent intermediate part design, feature analysis and compensation, are discussed. A number of case studies illustrating the manufacture of accurate parts in aluminium, stainless steel and titanium grade-2 alloy are discussed.

A novel multi-step strategy of single point incremental forming for high wall angle shape

2020 ◽  
Vol 56 ◽  
pp. 697-706 ◽  
Author(s):  
Song Wu ◽  
Yunwu Ma ◽  
Leitao Gao ◽  
Yixi Zhao ◽  
Sherif Rashed ◽  
...  
Keyword(s):  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Wall Angle

scholarly journals Study on Thickness Thinning Ratio of the Forming Parts in Single Point Incremental Forming Process

2018 ◽  
Vol 2018 ◽  
pp. 1-11 ◽  
Author(s):  
Mingshun Yang ◽  
Zimeng Yao ◽  
Yan Li ◽  
Pengyang Li ◽  
Fengkui Cui ◽  
...  
Keyword(s):  
Deformation Zone ◽  
Incremental Forming ◽  
Single Point ◽  
Sheet Thickness ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Feeding Speed ◽  
Forming Angle ◽  
Tool Diameter ◽  
Thinning Rate

An excessive thickness-reducing ratio of the deformation zone in single point incremental forming of the metal sheet process has an important influence on the forming limit. Prediction of the deformation zone thickness is an important approach to control the thinning ratio. Taking the 1060 aluminum as the research object, the principle of thickness deformation in the single point incremental forming process was analyzed; the finite element model was established using ABAQUS. A formula with high accuracy to predict the deformation zone thickness was fitted with the simulation results, and the influences of process parameters, such as tool diameter, step down, feeding speed, sheet thickness, and forming angle, on thinning ratio were analyzed. The accuracy of the finite element simulation was verified by experiment. A method to control the thinning rate by changing the forming trajectory was proposed. The results showed that the obtained value by using the fitted formula is closer to the experimental results than that obtained by the sine theorem. The thinning rate of the deformation zone increases with the increase of tool diameter, forming angle, and sheet thickness and decreases with the increase of step down, while the feeding speed had no significant effect on the thinning ratio. The most important factor of the thinning ratio is the forming angle, and the thinning ratio can be effectively reduced by using the forming trajectory with a uniformly distributed pressing point.

Experimental and Simulation Study of Single Point Incremental Forming of Polycarbonate

2019 ◽  
Author(s):  
Saurabh Rai ◽  
Rakesh Kumar ◽  
Harish Kumar Nirala ◽  
Kevin Francis ◽  
Anupam Agrawal
Keyword(s):  
Incremental Forming ◽  
Single Point ◽  
Material Strength ◽  
Displacement Curve ◽  
Single Point Incremental Forming ◽  
Aircraft Industry ◽  
Forming Process ◽  
Wall Angle ◽  
Safety Glass ◽  
Force Displacement

Abstract Single point incremental forming (SPIF) is more accurate and economical than the conventional forming process for customized products. Majority of the work in SPIF has been carried out on metals. However, polymers are also required to shape. Polycarbonate has wide application in safety glass, bottles, automotive and aircraft industry due to its transparent as well as attractive processing and mechanical properties as compared to other polymeric plastics. In present work, the Polycarbonate (PC) sheet of thickness 1.8 mm is deformed to make a square cup at different angles. Tensile testing is done to analyze the effect of wall angle on the deformed cup. This work illustrates the effect of the SPIF process on material strength in a different directions (vertical and horizontal) of the final deformed product. Tool forces are evaluated using ABAQUS® simulation for SPIF. Numerical simulation approach is used to calculate the fracture energy, which utilizes the force-displacement curve of the specimen and is verified.

Effect of Incremental Depth and Part Shape on Failure Modes in Single Point Incremental Forming of Polymers

2015 ◽  
Author(s):  
Mohammad Ali Davarpanah ◽  
Rajiv Malhotra
Keyword(s):  
Failure Modes ◽  
Incremental Forming ◽  
Single Point ◽  
Rate Of Change ◽  
Single Point Incremental Forming ◽  
Wall Angle ◽  
Cold Forming ◽  
Modes Of Failure ◽  
Polymer Sheets ◽  
Significant Research

Single Point Incremental Forming (SPIF) has received considerable attention recently due to advantages such as part-shape-independent tooling, higher formability and higher process flexibility as compared to conventional forming. While significant research has been performed on SPIF of metals, recent work has also shown the feasibility of using SPIF for cold-forming of thermoplastic polymer sheets. However, the effects of incremental depth and part shape on the modes of failure during polymer SPIF have rarely been investigated. This paper examines the effects of part shape and incremental depth on the formability and failure modes in polymer SPIF. It is shown that greater incremental depths result in greater formability in polymer SPIF. Furthermore, it is shown that increasing the rate of change of the wall angle with the Z depth of the part increases the maximum formability achievable using a given incremental depth. At the same time, it is observed that this dual advantage of greater formability and reduced forming time, possible with higher incremental depths, is limited by the occurrence of sheet wrinkling when the incremental depth becomes too high. Additionally, the dependence of sheet wrinkling on the overall shape of the part being formed is also shown.

Improvement of Formability in Single Point Incremental Forming of DP 1000 Steel by Induction Heating

2015 ◽  
Vol 794 ◽  
pp. 67-74
Author(s):  
Amar Al-Obaidi ◽  
Verena Kräusel ◽  
Dirk Landgrebe
Keyword(s):  
Induction Heating ◽  
Steel Sheet ◽  
Incremental Forming ◽  
Heating Temperature ◽  
Single Point ◽  
Operational Efficiency ◽  
Single Point Incremental Forming ◽  
Lower Side ◽  
Wall Angle ◽  
Optimum Heating

This paper provides results from experiments to improve formability of DP 1000 steel in forming a complex profiles in single point incremental forming with induction heating. High attention is rewarded to the straight effect of induction power and tool settings, in order to determine if the heating temperature is sufficient for raising the formability. The steel sheet is formed by a punch in the upper side and synchronized by induction heating for the sheet on the lower side. Investigations show a maximum achievable wall angle of 70°, which was accomplished at 20 kW induction power for the two formed shapes pyramid and cone. The operational efficiency improved by reducing both the forming time and the induction power required obtaining an optimum heating temperature for the sheet blank. The presented method can be used to increase the formability of difficult-to-form metals by using a simple setup.

Investigations on the void coalescence and corrosion behaviour of titanium grade 4 sheets during single point incremental forming process

2019 ◽  
Vol 66 (6) ◽  
pp. 861-867 ◽  
Author(s):  
G. Yoganjaneyulu ◽  
Y. Phaneendra ◽  
V.V. Ravikumar ◽  
C. Sathiya Narayanan
Keyword(s):  
Electron Microscope ◽  
Incremental Forming ◽  
Corrosion Behaviour ◽  
Single Point ◽  
Void Coalescence ◽  
Single Point Incremental Forming ◽  
Nacl Solution ◽  
Corrosion Morphology ◽  
Content Type ◽  
Titanium Grade

Purpose The purpose of this paper is to investigate the void coalescence and corrosion behaviour of titanium Grade 4 sheets during single point incremental forming (SPIF) process with various spindle rotational speeds. The development of corrosion pits in 3.5 (%) NaCl solution has also been studied during SPIF process. Design/methodology/approach In this current research work, the void coalescence analysis and corrosion behaviour of titanium Grade 4 specimens were studied. A potentio-dynamic polarization (PDP) study was conducted to investigate the corrosion behaviour of titanium Grade 4 processed samples with various spindle speeds in 3.5 (%) NaCl solution. The scanning electron microscope and transmission electron microscope analysis was carried out to study the fracture behaviour and corrosion morphology of processed samples. Findings The titanium Grade 4 sheets obtained better formability and corrosion resistance by increasing the CNC spindle rotational speeds. In fact that, the significant plastic deformation affects the corrosion rate with various spindle speeds were recorded. Originality/value The spindle rotational speeds and vertical step depths increases then the titanium Grade 4 sheets showed better formability, void coalescence and corrosion behaviour as the same is evidenced in forming limit diagram and PDP curves.

STUDY ON FORMING FORCES OF PARTS PROCESSED BY SINGLE POINT INCREMENTAL FORMING WITH DUMMY SHEET

2019 ◽  
Vol 14 (3) ◽  
Author(s):  
Vikas Sisodia ◽  
Shailendra Kumar
Keyword(s):  
Process Parameters ◽  
Feed Rate ◽  
Incremental Forming ◽  
Single Point ◽  
Sheet Thickness ◽  
Single Point Incremental Forming ◽  
Forming Force ◽  
Step Size ◽  
Wall Angle ◽  
Influence Of Process Parameters

The present paper describes the experimental investigation on influence of process parameters on maximum forming force in Single Point Incremental Forming (SPIF) process using dummy sheet. Process parameters namely dummy sheet thickness, tool size, step size, wall angle and feed rate are selected. Taguchi L18 orthogonal array is used to design the experiments. From the analysis of variance (ANOVA) dummy sheet thickness, tool size, step size and wall angle are significant process parameters while feed rate is insignificant. It is found that as dummy sheet thickness, tool size, step size and wall angle increase magnitude of peak forming force increases while there is marginal decrease in forming force as feed rate increases. Predictive model is also developed for forming force. Validation tests are performed in order to check the accuracy of developed model. Optimum set of process parameters is also determined to minimize forming force. Experimental results are in good agreement with results predicted by the developed mathematical model.

On the Effect of Curvature Radius on the Spif-Ability

2010 ◽  
Vol 129-131 ◽  
pp. 1222-1227 ◽  
Author(s):  
Ghulam Hussain ◽  
Gao Lin ◽  
Nasir Hayat ◽  
Asif Iqbal
Keyword(s):  
Sheet Metal Forming ◽  
Metal Forming ◽  
Incremental Forming ◽  
Single Point ◽  
Curvature Radius ◽  
Single Point Incremental Forming ◽  
Test Results ◽  
Forming Process ◽  
Wall Angle ◽  
Metal Forming Process

Single Point Incremental Forming (SPIF) is a novel sheet metal forming process. The formability (i.e. spif-ability) in this process is determined through Varying Wall Angle Conical Frustum (VWACF) test. In this paper, the effect of variation in the curvature radius, a geometrical parameter of test, on the test results is investigated. A series of VWACF tests with a variety of curvature radii is performed to quantify the said effect. It is found that the spif-ability increases with increasing of curvature radius. However, any variation in the curvature radius does not affect the spif-ability when the normalized curvature radius (i.e. curvature radius/tool radius) becomes higher than 9.

scholarly journals Influences of Vibration Parameters on Formability of 1060 Aluminum Sheet Processed by Ultrasonic Vibration-Assisted Single Point Incremental Forming

2019 ◽  
Vol 2019 ◽  
pp. 1-12
Author(s):  
Mingshun Yang ◽  
Lang Bai ◽  
Yan Li ◽  
Qilong Yuan
Keyword(s):  
Ultrasonic Vibration ◽  
Incremental Forming ◽  
Single Point ◽  
Aluminum Sheet ◽  
Forming Limit ◽  
Single Point Incremental Forming ◽  
Experimental Platform ◽  
Formed Part ◽  
Vibration Parameters ◽  
Forming Angle

With increasing design complexities of thin-walled parts, the requirement of enhanced formability has impeded the development of the single point incremental forming (SPIF) process. In the present research, the ultrasonic vibration-assisted single point incremental forming (UV-SPIF) method was introduced to increase the formability of sheet metals. AL1060 aluminum alloy was adopted as the experimental material, and a truncated cone part was considered as the research object. The simulation model of UV-SPIF was established to analyze the distribution of plastic strains in the formed part. A forming angle was selected as the measuring index of formability of the aluminum sheet, and the influences of different vibration parameters on formability were evaluated. An experimental platform was devised to verify the accuracy of the obtained simulation results. It was found that ultrasonic vibration effectively improved the forming limit of the sheet. When the amplitude was 6 µm and the frequency was 25 kHz, the sheet yielded the best formability with the largest forming angle of 67 degrees.

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