Abstract
In incremental sheet forming (ISF), including single point incremental forming (SPIF) and double side incremental forming (DSIF), the material formability can be significantly enhanced when compared with conventional sheet forming processes. The material deformation in ISF is far more complicated because of the combined material deformation under stretching, bending, shearing, and cyclic loading, with an additional effect of compression in DSIF. Despite extensive investigation on material deformation during ISF, no theory has yet been widely agreed to explain different types of the material fracture behavior observed in ISF experiments. This paper presents a comprehensive review on the formability enhancement in ISF and proposes possible fracture mechanisms explaining the different types of fracture behavior observed in the experimental investigations. Discussions are presented to outline the current research progress and possible solutions to overcome the current ISF process limitations because of the material processing failure due to fracture.
Highlights
Incremental sheet forming (ISF) is a flexible, cost-effective, and energy-efficient sheet forming process, suitable for prototype and customized sheet metal products
The movement of the tools is determined by the coordinates predefined by the toolpath generation algorithms. It will result in less accurate thickness distribution of the sheet in DISF if the supporting tool is not placed in the ideal position, or excessive thinning of the sheet or the deflection of the structures occurs if the supporting tool will lose its contact with the sheet; double side incremental forming (DSIF) degenerates to single point incremental forming (SPIF)
This paper presents a complete review on investigation of material fracture in the ISF process, including SPIF and DSIF
Summary
Incremental sheet forming (ISF) is a flexible, cost-effective, and energy-efficient sheet forming process, suitable for prototype and customized sheet metal products. According to the experimental tests and finite element (FE) simulations, it has been widely acknowledged that the material plastic deformation in SPIF is limited to the contact area between the tool and the metal sheet. The deformation mode of the material was confirmed to be a combination of stretching, bending, and shearing by conducting investigations through experimental and FE simulations. Comprehensive literature reviews on the effect of process parameters on the material formability in ISF, including tool dimensions, vertical step down, and sheet thickness, have been reported recently by Gatea et al [22] and McAnulty et al [23]. Compared with a great amount of research reported on the deformation mechanism of ISF, the study on the initiation and evolution of the material fracture in ISF, especially in DSIF, is very limited. ISF has shown great potential in manufacturing of non-metallic materials, such as PVC and polymers [29, 30], the scope of this review paper will focus on metallic materials only
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