Incremental sheet forming of thermoplastics: a review

Zhu, Hui; Ou, Hengan; Popov, Atanas A.

doi:10.1007/s00170-020-06056-5

Cited by 40 publications

(19 citation statements)

References 93 publications

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“…Consequently, different concepts have recently been developed for warm SPIF to enhance a material's formability and to improve geometrical accuracy. A review and analysis of the state-of-the-art research on hot incremental sheet forming has been conducted by Liu [279] and by Zhu et al [280]. This hybrid forming technology has first been applied to metal sheets [281][282][283][284][285][286][287] and later to polymer sheets [267,[288][289][290][291][292][293][294].…”

Section: Application Of Spif To Hybrid Metal-polymer Compositesmentioning

confidence: 99%

New Advances and Future Possibilities in Forming Technology of Hybrid Metal–Polymer Composites Used in Aerospace Applications

et al. 2021

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Fibre metal laminates, hybrid composite materials built up from interlaced layers of thin metals and fibre reinforced adhesives, are future-proof materials used in the production of passenger aircraft, yachts, sailplanes, racing cars, and sports equipment. The most commercially available fibre–metal laminates are carbon reinforced aluminium laminates, aramid reinforced aluminium laminates, and glass reinforced aluminium laminates. This review emphasises the developing technologies for forming hybrid metal–polymer composites (HMPC). New advances and future possibilities in the forming technology for this group of materials is discussed. A brief classification of the currently available types of FMLs and details of their methods of fabrication are also presented. Particular emphasis was placed on the methods of shaping FMLs using plastic working techniques, i.e., incremental sheet forming, shot peening forming, press brake bending, electro-magnetic forming, hydroforming, and stamping. Current progress and the future directions of research on HMPCs are summarised and presented.

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Section: Application Of Spif To Hybrid Metal-polymer Compositesmentioning

confidence: 99%

New Advances and Future Possibilities in Forming Technology of Hybrid Metal–Polymer Composites Used in Aerospace Applications

et al. 2021

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“…Since the process is rather distinct in comparison to other processes of sheet metal forming, special design rules were presented by Afonso et al [ 5 ]. The process was first used solely for the production of metal parts [ 6 , 7 , 8 ], but in recent years, various polymer materials have also been successfully processed by IF technologies [ 9 ].…”

Section: Introductionmentioning

confidence: 99%

Finite Element Simplifications and Simulation Reliability in Single Point Incremental Forming

et al. 2022

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Single point incremental forming (SPIF) is one of the most promising technologies for the manufacturing of sheet metal prototypes and parts in small quantities. Similar to other forming processes, the design of the SPIF process is a demanding task. Nowadays, the design process is usually performed using numerical simulations and virtual models. The modelling of the SPIF process faces several challenges, including extremely long computational times caused by long tool paths and the complexity of the problem. Path determination is also a demanding task. This paper presents a finite element (FE) analysis of an incrementally formed truncated pyramid compared to experimental validation. Focus was placed on a possible simplification of the FE process modelling and its impact on the reliability of the results obtained, especially on the geometric accuracy of the part and bottom pillowing effect. The FE modelling of SPIF process was performed with the software ABAQUS, while the experiment was performed on a conventional milling machine. Low-carbon steel DC04 was used. The results confirm that by implementing mass scaling and/or time scaling, the required calculation time can be significantly reduced without substantially affecting the pillowing accuracy. An innovative artificial neural network (ANN) approach was selected to find the optimal values of mesh size and mass scaling in term of minimal bottom pillowing error. However, care should be taken when increasing the element size, as it has a significant impact on the pillow effect at the bottom of the formed part. In the range of selected mass scaling and element size, the smallest geometrical error regarding the experimental part was obtained by mass scaling of 19.01 and tool velocity of 16.49 m/s at the mesh size of 1 × 1 mm. The obtained results enable significant reduction of the computational time and can be applied in the future for other incrementally formed shapes as well.

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“…Because of the unique characteristics of single point incremental forming, such as flexibility, cost-effectiveness, shortened time-to-market, and increased forming limit, the SPIF is a potential technology that can be developed further as an alternative production approach for composite sheets [1][2][3][4]. The impact of T6 treatment on the tensile properties of Al6061 and Al7108/SiCp composites was examined and compared to samples prior to T6 treatment.…”

Section: Introductionmentioning

confidence: 99%

Numerical and experimental investigation of formability in incremental sheet forming of particle-reinforced metal matrix composite sheets

Gatea

Tawfiq

2022

Int J Adv Manuf Technol

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Metal matrix composites (MMCs) have a high strength-to-weight ratio, high stiffness, and good damage resistance under a wide range of operating conditions, making them a viable alternative to traditional materials in a variety of technical applications. Because of their high strength, composite materials are hard to deform to a significant depth at room temperature.As a result, additional treatments are required to enhance the composite's room ductility prior to deformation. In this investigation, as-received 6092Al/SiCp composite sheets (T6-condition) are heat treated to O-condition annealing to enhance its ductility in order to assess the influence of single point incremental forming (SPIF) parameters on the formability and fracture behavior of the Al/SiC particle composite sheets at room temperature. Then the annealed sheets are heat treated to T6-condition to enhance the strength and achieve properties equivalent to as-received sheets properties. The results demonstrate that the Al/SiC particle composite sheets with T6 treatment could not be deformed to the specified depth at room temperature due to low room ductility and that further treatment, such as Ocondition annealing, is required to enhance the room ductility. When annealed Al/SiCp composite sheets are heat treated to T6, the sheets exhibit properties comparable to the asreceived sheets. Al/SiC particle composite sheets with low SPIF parameters may have greater formability and fracture depth with low strain hardening curve.

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Incremental sheet forming of thermoplastics: a review

Cited by 40 publications

References 93 publications

New Advances and Future Possibilities in Forming Technology of Hybrid Metal–Polymer Composites Used in Aerospace Applications

New Advances and Future Possibilities in Forming Technology of Hybrid Metal–Polymer Composites Used in Aerospace Applications

Finite Element Simplifications and Simulation Reliability in Single Point Incremental Forming

Numerical and experimental investigation of formability in incremental sheet forming of particle-reinforced metal matrix composite sheets

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