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Review

State of the Art in Incremental Forming: Process Variants, Tooling, Industrial Applications for Complex Part Manufacturing and Sustainability of the Process

by
Gabriela-Petruța Popp
1,
Sever-Gabriel Racz
1,
Radu-Eugen Breaz
2,*,
Valentin Ștefan Oleksik
1,
Mihai-Octavian Popp
1,
Dana-Elena Morar
2,
Anca-Lucia Chicea
1 and
Ilie-Octavian Popp
1
1
Department of Industrial Machines and Equipment, Engineering Faculty, Lucian Blaga University of Sibiu, 550025 Sibiu, Romania
2
Department of Civil Construction and Management, Faculty of Civil Engineering, Technical University of Cluj-Napoca, 400114 Cluj-Napoca, Romania
*
Author to whom correspondence should be addressed.
Materials 2024, 17(23), 5811; https://doi.org/10.3390/ma17235811
Submission received: 16 October 2024 / Revised: 18 November 2024 / Accepted: 20 November 2024 / Published: 27 November 2024
(This article belongs to the Special Issue Research on Metal Cutting, Casting, Forming, and Heat Treatment)
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Abstract

This paper explores the development and application of the incremental forming process, an innovative method for manufacturing complex parts with high flexibility and low tooling costs. The review categorizes three key process variants: Single Point Incremental Forming (SPIF), Two Point Incremental Forming (TPIF), and Incremental Forming with Conjugated Active Plate (IFCAP). This study demonstrates the significant effects of these process variants on part accuracy and material behavior, particularly under varying process conditions. This study identifies critical technological parameters such as tool diameter, feed rate, and vertical step size. The findings also demonstrate the role of optimized toolpaths and lubrication in improving process efficiency. Applications of incremental forming across various industries, including automotive, aerospace, medical, and construction, demonstrate its versatility in prototype production and small-series manufacturing. These results contribute to a deeper understanding of incremental forming, offering practical recommendations to enhance precision, scalability, and material formability, and supporting future innovations and broader industrial applications.
Keywords: incremental forming; state-of-the-art; single point incremental forming (SPIF); two point incremental forming (TPIF); conjugated active plate; complex part manufacturing; dimensional accuracy; surface quality; tooling; industrial applications incremental forming; state-of-the-art; single point incremental forming (SPIF); two point incremental forming (TPIF); conjugated active plate; complex part manufacturing; dimensional accuracy; surface quality; tooling; industrial applications
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MDPI and ACS Style

Popp, G.-P.; Racz, S.-G.; Breaz, R.-E.; Oleksik, V.Ș.; Popp, M.-O.; Morar, D.-E.; Chicea, A.-L.; Popp, I.-O. State of the Art in Incremental Forming: Process Variants, Tooling, Industrial Applications for Complex Part Manufacturing and Sustainability of the Process. Materials 2024, 17, 5811. https://doi.org/10.3390/ma17235811

AMA Style

Popp G-P, Racz S-G, Breaz R-E, Oleksik VȘ, Popp M-O, Morar D-E, Chicea A-L, Popp I-O. State of the Art in Incremental Forming: Process Variants, Tooling, Industrial Applications for Complex Part Manufacturing and Sustainability of the Process. Materials. 2024; 17(23):5811. https://doi.org/10.3390/ma17235811

Chicago/Turabian Style

Popp, Gabriela-Petruța, Sever-Gabriel Racz, Radu-Eugen Breaz, Valentin Ștefan Oleksik, Mihai-Octavian Popp, Dana-Elena Morar, Anca-Lucia Chicea, and Ilie-Octavian Popp. 2024. "State of the Art in Incremental Forming: Process Variants, Tooling, Industrial Applications for Complex Part Manufacturing and Sustainability of the Process" Materials 17, no. 23: 5811. https://doi.org/10.3390/ma17235811

APA Style

Popp, G.-P., Racz, S.-G., Breaz, R.-E., Oleksik, V. Ș., Popp, M.-O., Morar, D.-E., Chicea, A.-L., & Popp, I.-O. (2024). State of the Art in Incremental Forming: Process Variants, Tooling, Industrial Applications for Complex Part Manufacturing and Sustainability of the Process. Materials, 17(23), 5811. https://doi.org/10.3390/ma17235811

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