Advanced manufacturing techniques aimed at implants with high dependability, flexibility, and low manufacturing costs are crucial in meeting the growing demand for high-quality products such as biomedical implants. Incremental sheet forming is a promising flexible manufacturing approach for rapidly prototyping sheet metal components using low-cost tools. Titanium and its alloys are used to shape most biomedical implants because of their superior mechanical qualities, biocompatibility, low weight, and great structural strength. The poor formability of titanium sheets at room temperature, however, limits their widespread use. The goal of this research is to show that the gradual sheet formation of a titanium biomedical implant is possible. The possibility of creative and cost-effective concepts for the manufacture of such complicated shapes with significant wall angles is explored. A numerical simulation based on finite element modeling and a design process tailored for metal forming are used to complete the development. The mean of uniaxial tensile tests with a constant strain rate was used to study the flow behavior of the studied material. To forecast cracks, the obtained flow behavior was modeled using the behavior and failure models.
Advanced manufacturing techniques, aimed at implants with high dependability, flexibility, and low manufacturing costs, are crucial in meeting the growing demand for high-quality products like biomedical implants. Incremental sheet forming is a promising flexible manufacturing approach for rapidly prototyping sheet metal components using low-cost tools. Titanium and its alloys are used to shape most biomedical implants because of its superior mechanical qualities, biocompatibility, low weight, and great structural strength. The poor formability of titanium sheets at room temperature, however, limits their widespread use. The goal of this research is to show that gradual sheet formation of a titanium biomedical implant is possible. The possibility of creative and cost-effective concepts for the manufacturing of such complicated shapes with significant wall angles is explored in this study. A numerical simulation based on finite element modeling as well as a design process tailored to metal forming is used to complete the development. The mean of uniaxial tensile tests with a constant strain rate was used to study the flow behavior of the studied material. To forecast the crack, the obtained flow behavior was modeled using the behavior model and failure model.
Incremental sheet metal forming is a flexible manufacturing technology that allows to form of various components on the same milling machine, without expensive tools. A hemispherical tool moves along a CNC-controlled tool path and deforms the sheet into the desired shape. The tool path has a significant role in the geometric accuracy of the final part. There has been very little research on the problem of the forming of sophisticated parts with asymmetric wall angles. This paper presents a new approach to generating optimized tool paths for single-point incremental sheet forming (SPIF). At first, a strategy is proposed for the automatic generation of a 3D tool path during forming in a single-step operation. Then, a systematic technique of creating intermediate shapes is investigated by defining tool paths interpolated from the final part shape. The proposed methodology is applied to form a hip cup prosthesis. This part has a complex asymmetric geometry with important angles, a multi-step approach is used. The proposed methodology to define the different tool paths was implemented in Matlab. A numerical simulation of the incremental forming process is performed to predict the final geometry of the aluminum sheet. A comparison of desired and predicted geometries shows the reliability of the proposed method.
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