A five stage forming strategy for Single Point Incremental Forming of a circular cylindrical cup with a height/radius ratio of one is presented. Geometrical relations are discussed and theoretical strains are calculated. The influence of forming direction (upwards or downwards) is investigated for the second stage comparing explicit FE analysis with experiments. Good agreement is found between calculated and measured thickness distribution, overall geometry and strains. Using the proposed multi stage strategy it is shown possible to produce a cup with a height close to the radius and sides parallel to the symmetry axis in about half of the dept

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The computational-costs for finite element simulations of general sheet metal forming processes are considerable, especially measured in time. In combination with optimization, the performance of the optimization algorithm is crucial for the overall performance of the system, i.e. the optimization algorithm should gain as much information about the system in each iteration as possible. Least-square formulation of the object function is widely applied for solution of inverse problems, due to the superior performance of this formulation. In this work focus will be on small problems which are defined as problems with less than 1000 design parameters; as the majority of real life optimization and inverse problems, represented in literature, can be characterized as small problems, typically with less than 20 design parameters. We will show that the least square formulation is well suited for two classes of inverse problems; identification of constitutive parameters and process optimization. The scalability and robustness of the approach are illustrated through a number of process optimizations and inverse material characterization problems; tube hydro forming, two step hydro forming, flexible aluminum tubes, inverse identification of material parameters.

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We investigated if injectable calcium phosphate cement improves primary stability in open-wedge high-tibial osteotomy. A 10 mm open-wedge osteotomy was performed on eight pairs of preserved cadaver tibiae and seven pairs of composite (Sawbone) left tibiae. Osteosynthesis was performed with the Dynafix plate system. The gap resulting from surgery either was filled with 15 g injectable calcium phosphate cement in half the bones or was left untreated. The composite tibiae were loaded at a ramp speed of 20 mm/min up to 20 kN. The cadaver tibiae were exposed to 100 cycles with a maximum compressive force of 2,250 N. After 100 cycles of loading with 2,250 N, the final loaded displacement was 1.2 mm for the cadaver tibiae treated with injectable calcium phosphate cement as compared with 3.6 mm for the empty defects (P = 0.028). All the seven empty defect composite specimens failed prior to 20 kN (median 2.8 kN) as compared with five of the injectable calcium phosphate cement specimens (median 17 kN) (P = 0.005). The injection of injectable calcium phosphate cement following open-wedge osteotomy of the proximal tibia increases the initial stability of the bone as measured by load-to-failure and displacement after cyclic loading. Clinical studies are ongoing to investigate whether injectable calcium phosphate cement also has clinical advantage on wedge healing and stability.

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