Manufacture of Accurate Titanium Cranio-Facial Implants with High Forming Angle Using Single Point Incremental Forming

Duflou, Joost R.; Behera, Amar Kumar; Vanhove, Hans; Bertol, Liciane Sabadin

doi:10.4028/www.scientific.net/kem.549.223

Cited by 52 publications

(27 citation statements)

References 10 publications

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“…Approaches to improve the accuracy have included toolpath optimization techniques [15][16][17][18], use of in-process heating techniques such as laser support or electric heating to soften the material and thereby reduce spring back and plastic deformation [19,20], feature analysis based techniques [21,22], use of tooling strategies [23] etc. Limited improvement in accuracy of titanium sheet parts was demonstrated for a TPIF process using laser support by Göttmann et al [24] and for SPIF by compensating part geometry by Behera et al [25].…”

Section: Introductionmentioning

confidence: 99%

Effect of stress relieving heat treatment on surface topography and dimensional accuracy of incrementally formed grade 1 titanium sheet parts

Behera

2016

Int J Adv Manuf Technol

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The forming of parts with an optimized surface roughness and high dimensional accuracy is important in many applications of incremental sheet forming (ISF). To realize this, the effect of stress relieving heat treatment of grade-1 Ti parts performed before and after forming on the surface finish and dimensional accuracy was studied. It was found that heat treatment at a temperature of 540°C for 2 h improves the surface finish of formed parts resulting in a surface with little or no visible tool marks. Additionally, it improves the dimensional accuracy of parts after unclamping from the rig used for forming, in particular, that of parts with shallow wall angles (typically <25°). It was also noted that post-forming heat treatment improves the surface finish of parts. The surface topography of formed parts was studied using interferometry to yield areal surface roughness parameters and subsequently using secondary electron imaging. Back-scatter electron microscopy imaging results coupled with energy-dispersive Xray (EDX) analysis showed that heat treatment prior to forming leads to tool wear as indicated by the presence of Fe in samples. Furthermore, post-forming heat treatment prevents curling up of formed parts due to compressive stresses if the formed part is trimmed.

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Section: Introductionmentioning

confidence: 99%

Effect of stress relieving heat treatment on surface topography and dimensional accuracy of incrementally formed grade 1 titanium sheet parts

Behera

2016

Int J Adv Manuf Technol

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“…Even though Behera et al [2] tried forming implant shapes with high forming angles with improved accuracy, the part made of titanium grade II failed. The work of Göttmann [3] illustrated the ability to form implants with a maximum deviation at the edges just less than 2 mm using two point incremental forming (TPIF).…”

Section: Introductionmentioning

confidence: 99%

“…Despite a number of efforts to make medical implant shapes using ISF [2][3][4][5][6][7][8], making these parts with high accuracy has been a problem. Even though Behera et al [2] tried forming implant shapes with high forming angles with improved accuracy, the part made of titanium grade II failed.…”

Section: Introductionmentioning

confidence: 99%

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Characterization of shape and dimensional accuracy of incrementally formed titanium sheet parts with intermediate curvatures between two feature types

Behera

Lü

2015

Int J Adv Manuf Technol

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Single point incremental forming (SPIF) is a relatively new manufacturing process that has been recently used to form medical grade titanium sheets for implant devices. However, one limitation of the SPIF process may be characterized by dimensional inaccuracies of the final part as compared with the original designed part model. Elimination of these inaccuracies is critical to forming medical implants to meet required tolerances. Prior work on accuracy characterization has shown that feature behavior is important in predicting accuracy. In this study, a set of basic geometric shapes consisting of ruled and freeform features were formed using SPIF to characterize the dimensional inaccuracies of grade 1 titanium sheet parts. Response surface functions using multivariate adaptive regression splines (MARS) are then generated to model the deviations at individual vertices of the STL model of the part as a function of geometric shape parameters such as curvature, depth, distance to feature borders, wall angle, etc. The generated response functions are further used to predict dimensional deviations in a specific clinical implant case where the curvatures in the part lie between that of ruled features and freeform features. It is shown that a mixed-MARS response surface model using a weighted average of the ruled and freeform surface models can be used for such a case to improve the mean prediction accuracy within ±0.5 mm. The predicted deviations show a reasonable match with the actual formed shape for the implant case and are used to generate optimized tool paths for minimized shape and dimensional inaccuracy. Further, an implant part is then made using the accuracy characterization functions for improved accuracy. The results show an improvement in shape and dimensional accuracy of incrementally formed titanium medical implants.

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“…From Computerized Tomography (CT) images of a fractured skull, a CAD model of the skull BioModeling and a restorative implant were constructed digitally. Duflou et al [6] used three different materials: AA1050, AISI 304 and medical grade titanium for accurate manufacture of cranio-facial implant using single point incremental forming process.…”

Section: Introductionmentioning

confidence: 99%

Finite Element Analysis of hot Single Point Incremental forming of hip prostheses

et al. 2016

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Abstract. The titanium alloy Ti-6Al-4V is one of the most frequently used materials for biomedical applications due to its biocompatibility and excellent mechanical properties. However, wide usage of Ti-6Al-4V sheet is limited by its poor room-temperature formability. Therefore, hot Single Point Incremental Forming (SPIF) has been used to improve its formability. This paper aims at proving the feasibility of the hot incremental forming of an acetabular component of hip prosthesis by Finite Element simulations. The effect of process parameters, namely the forming temperature and the punch diameter on the geometric accuracy and the failure of the final product are investigated.

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Manufacture of Accurate Titanium Cranio-Facial Implants with High Forming Angle Using Single Point Incremental Forming

Cited by 52 publications

References 10 publications

Effect of stress relieving heat treatment on surface topography and dimensional accuracy of incrementally formed grade 1 titanium sheet parts

Effect of stress relieving heat treatment on surface topography and dimensional accuracy of incrementally formed grade 1 titanium sheet parts

Characterization of shape and dimensional accuracy of incrementally formed titanium sheet parts with intermediate curvatures between two feature types

Finite Element Analysis of hot Single Point Incremental forming of hip prostheses

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