Abstract
There has been increasing interest in the processes that enable part customization and small-batch production in recent years. The prosthetic sector, in which biocompatible materials are used, is one of the areas that requires these types of processes; Incremental Sheet Forming (ISF) technology can meet these requirements. However, the biocompatible thermoplastic polymers formed by this technology have not yet been tested. Hence, the aim of this paper is to cover this gap in our knowledge by analyzing the effects of process parameters on the ISF process with the aim of optimizing these parameters before the actual production of, in this case, customized prostheses. Tests with polycaprolactone (PCL) and ultra-high molecular weight polyethylene (UHMWPE) were performed. Maximum force, surface roughness and maximum depth were statistically analyzed by means of response surface methodology and survival analysis. Spindle speed and tool diameter were shown to be the most influential process parameters in terms of maximum forming force and surface roughness for both materials. In contrast, survival analysis applied to maximum depth showed a greater influence of tool diameter in PCL sheets and a greater influence of spindle speed in the case of UHMWPE.
Highlights
The paradigms of manufacturing have evolved from craft production to mass production and from mass customization to what S
SPIF experimental tests using two different polymers biocompatible have been carried out following a Box-Behnken design for four factors and a survival analysis
The maximum carried out following a Box-Behnken design for four factors and a survival analysis
Summary
The paradigms of manufacturing have evolved from craft production to mass production and from mass customization to what S. J. Hu [1] calls personalization or personalized production. There are several important concepts and technologies that have facilitated the development of personalized production, including open-architecture products, personalization design, on-demand manufacturing systems and cyber-physical systems. In the context of on-demand manufacturing systems, Incremental Sheet Forming (ISF) emerged to meet the demand for rapid prototyping and small-batch production. The process consists of a sheet being formed by means of a round-tipped tool (or punch), which makes a series of small incremental deformations in the sheet on a predefined path that is governed by a numerical control. It is a simple process that can be applied in a number of different fields, ranging from the automotive and aeronautic sectors to architecture. It is struggling to find a place in industrial production beyond the Materials 2018, 11, 1377; doi:10.3390/ma11081377 www.mdpi.com/journal/materials
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