Incremental Forming of Titanium Ti6Al4V Alloy for Cranioplasty Plates—Decision-Making Process and Technological Approaches

Racz, Sever-Gabriel; Breaz, Radu-Eugen; Tera, Melania; Gîrjob, Claudia; Biriș, Cristina; Chicea, Anca Lucia; Bologa, Octavian

doi:10.3390/met8080626

Cited by 25 publications

(20 citation statements)

References 52 publications

(65 reference statements)

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“…Incremental sheet forming (ISF) is an advanced sheet forming process economically suitable for producing small-scaled batches for aerospace (e.g., noses and cones), biomedical (e.g., customized implants like human leg and skull), and automotive (e.g., car body panels and flanges) parts [1][2][3]. The forming tool in this process traverses the peripherally clamped sheet in an incremental fashion to produce a 3D geometry.…”

Section: Introductionmentioning

confidence: 99%

On the Free-Surface Roughness in Incremental Forming of a Sheet Metal: A Study from the Perspective of ISF Strain, Surface Morphology, Post-Forming Properties, and Process Conditions

Al‐Ghamdi

Hussain

2019

Metals

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Due to absence of any supporting die, the free surfaces in incremental sheet forming (ISF) experience uneven deformation. This results in rough surfaces, possibly leading to the reduced service life of components. Therefore, it is necessary to analyze and quantify the effects of the application of strain on the free-surface roughness. Moreover, in order to control roughness, both on the free surface and the opposite contact surface, the nature of correlation between the two types of roughnesses needs to be identified by classifying the significance of different process conditions. The present work is a fundamental study to address these points. A series of specimens are produced by subjecting a metallic sheet to a range of ISF strains (13% to 98%). These specimens are then subjected to a number of characterization tests, namely roughness, uniaxial tension, and residual stress tests. The results reveal that the mean free-surface roughness increases non-linearly as the normal strain (stretching + bending) on the free surface increases (where strain state on the surface is as follows: ɛ1 = 0, ɛ2 > 0, γmax = ɛ2 and 1 and 2 are principal directions). The roughness also increases, although linearly, with the post-forming sheet strength, residual stress, and forming force, thereby showing that strain hardening has a direct influence on the roughness in a way that sheet strengthening is achieved at the cost of surface quality. The surface morphology reveals that the free surfaces contained orange peel, slip lines, and micro-voids, with density increasing with strain application, thus indicating the possible influence of tensile stresses on free surface deformation and roughening at an increasing degree with strain. Further analysis of roughness results discloses that the free-surface roughness and the contact-surface roughness are inversely related, because the responses of the two to ISF processing were mutually exclusive. Based on the obtained results, future research directions are also discussed.

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Section: Introductionmentioning

confidence: 99%

On the Free-Surface Roughness in Incremental Forming of a Sheet Metal: A Study from the Perspective of ISF Strain, Surface Morphology, Post-Forming Properties, and Process Conditions

Al‐Ghamdi

Hussain

2019

Metals

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“…The cranioplasty plates can be made by cutting, SPIF [18], SPIF with heating, double-side incremental forming [11] or by super plastic forming [12]. The development of computer systems has led to the emergence of new technologies in the expansion of medical implants.…”

Section: Methodsmentioning

confidence: 99%

“…In this category can be mentioned selective laser sintering, direct metal laser sintering, fused deposition modeling, stereolitography apparatus and 3D printing (3DP). Jardini et al [12] reconstruct a 3D biomodel from the 3DP manufactured skull. Then they verify the adjustment on the 3D biomodel by using a titanium implant manufactured with DMLS.…”

Section: Methodsmentioning

confidence: 99%

A Brief Review of Manufacturing Medical Implants by Single Point Incremental Forming

Alexandru

2018

ACTA Universitatis Cibiniensis

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“…These errors tend to occurs at parts with different shapes and sizes and they are not dependent of the material used or the toolpaths of the punch. Of course, there are cases when some errors are more pronounced than the others are, but this is still not acceptable in automotive industry [4], [5], [8].…”

Section: Introductionmentioning

confidence: 99%

Numerical Study of a Process Strategy for Improving Geometrical Accuracy in Incremental Forming Process

Popp

Oleksik

Racz

et al. 2019

Acta Universitatis Cibiniensis. Technical Series

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Incremental forming process is a relatively new process among researchers, which is yet to be implemented in automotive and aerospace industries. The researchers are studying various process strategies and methods to improve the geometrical accuracy of the parts obtained by incremental forming, because the geometry of the parts is one of the key factors holding back the process industrialization. One good method to investigate the benefits of a process strategy is by means of numerical analysis, from which the results obtained can confirm or disprove the gains of the researched strategy. The aim of this paper is to present the advantages of using a fluid under pressure as a supporting die instead of using a conventional fixed backing plate for the single point incremental forming process.

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Incremental Forming of Titanium Ti6Al4V Alloy for Cranioplasty Plates—Decision-Making Process and Technological Approaches

Cited by 25 publications

References 52 publications

On the Free-Surface Roughness in Incremental Forming of a Sheet Metal: A Study from the Perspective of ISF Strain, Surface Morphology, Post-Forming Properties, and Process Conditions

On the Free-Surface Roughness in Incremental Forming of a Sheet Metal: A Study from the Perspective of ISF Strain, Surface Morphology, Post-Forming Properties, and Process Conditions

A Brief Review of Manufacturing Medical Implants by Single Point Incremental Forming

Numerical Study of a Process Strategy for Improving Geometrical Accuracy in Incremental Forming Process

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