Abstract
Incremental sheet forming (ISF) is a relatively new flexible forming process. ISF has excellent adaptability to conventional milling machines and requires minimum use of complex tooling, dies and forming press, which makes the process cost-effective and easy to automate for various applications. In the past two decades, extensive research on ISF has resulted in significant advances being made in fundamental understanding and development of new processing and tooling solutions. However, ISF has yet to be fully implemented to mainstream high-value manufacturing industries due to a number of technical challenges, all of which are directly related to ISF process parameters. This paper aims to provide a detailed review of the current state-of-the-art of ISF processes in terms of its technological capabilities and specific limitations with discussions on the ISF process parameters and their effects on ISF processes. Particular attention is given to the ISF process parameters on the formability, deformation and failure mechanics, springback and accuracy and surface roughness. This leads to a number of recommendations that are considered essential for future research effort.
Highlights
Incremental sheet forming (ISF) generally refers to a group of forming processes that may be characterised by localized deformations, and these deformations are proceeded progressively on a certain path to cover the whole surface of the part
The effect of some parameters, such as step size, on the formability of a commercially pure titanium blank was investigated by Hussain et al [44], and the results proved that the formability decreases linearly as the step size increases
The results showed that in single-point incremental forming (SPIF), the enhancement of formability above the forming limit curve at the necking (FLCN) increased as tool size decreases up to values around 150 % with tool diameter of 6 mm, while in the stretch-bending it remained around 30 % for both tool diameters (10 and 20 mm)
Summary
Incremental sheet forming (ISF) generally refers to a group of forming processes that may be characterised by localized deformations, and these deformations are proceeded progressively on a certain path to cover the whole surface of the part. Depending on this definition, there are several types of ISF, such us spinning, shear forming, flow forming and single- or two-point ISF. Several ISF techniques have been developed to make use of computer numerical controlled (CNC) equipment One of these methods, single-point incremental forming (SPIF), may be characterised by the action of a CNC milling machine tool that has a single-point contact with the sheet metal blank. A small-sized hemispheric tool moves along a user-defined path and incrementally creates the desired shape [2]
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