Abstract
Hole-flanging by single-point incremental forming (SPIF) is an emerging sheet forming process with a high potential economic payoff for rapid prototyping and small quantity production. So far, applications have only been performed in metals but the aim of this article is to evaluate the feasibility of using polymers. Special emphasis is given to the deformation mechanics of the process and the physics behind the occurrence of failure by fracture along the wall flange. The investigation draws from the independent determination of the mechanical properties, fracture toughness, and formability limits of polyethylene terephthalate (PET) and polycarbonate (PC), to experimentation in a CNC machining center equipped with an apparatus for multi-stage SPIF. The work is supported by circle grid analysis and results show that PET is appropriate for producing hole-flanged parts with vertical walls due to its capability of withstanding high levels of deformation at room temperature.
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