The last decade has seen considerable interest in flexible forming processes. Among the upcoming flexible forming techniques, one that has captured a lot of interest is Single Point Incremental Forming (SPIF), 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. Research on SPIF in the last ten years has focused on defining the limits of this process, understanding the deformation mechanics and material behavior and extending the process limits using various strategies. This paper captures the developments that have taken place over the last decade in academia and industry to highlight the current state of the art in this field. The use of different hardware platforms, forming mechanics, failure mechanism, estimation of forces, use of toolpath and tooling strategies, development of process planning tools, simulation of the process, aspects of sustainable manufacture and current and future applications are individually tracked to outline the current state of this process and provide a roadmap for future work on this process.
This paper comprises an experimental study for a complex geometry part obtained by incremental forming. Due to the process complexity (the presence of forces on three directions—a vertical one and two in the blank's plane), a three axes CNC milling machine, capable of describing the complex paths covered by the punch for obtaining the truncated cone-shaped parts, has been chosen. To obtain a truncated cone, three different trajectories were selected: in first and second variants after each vertical press having a constant step, the punch covers a circular path. The differences show that the following circular trajectory can start at the same point or can be shifted at an angle of 90° from the previous press point. In the last variant, the punch performs a spatial spiral trajectory. The main objective of our study was to determine the optimal forming strategy, by shifting the press position of the punch and the path it follows to obtain a truncated cone through single point incremental forming. Thus, the strain distribution can be homogeneous, and the thickness reduction and the process forces are minimal.
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.
The paper presents a study based on the experimental research on the surface quality of the medical implants used for the partial resurfacing of the femoral condylar surface of the knee obtained by single point incremental forming process. The present paper discusses the measuring of the roughness of parts obtained through the previously mentioned process and highlights the factors that influence it. The initial roughness of the punch, the punch diameter, and the friction coefficient between the punch and the blank were considered. Also, the mathematical models that define different roughness parameters were determined.
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