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Advanced Incremental Sheet Forming of Hard-to-Work Materials

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (20 May 2023) | Viewed by 1434

Special Issue Editor


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Guest Editor
Department of Chemical, Materials and Production Engineering, University of Naples Federico II, 80125 Naples, Italy
Interests: manufacturing and thermomechanical characterization of composite structures; incremental sheet forming of metals and polymers; manufacturing and characterization of metal foam structures; investigation of the wear behavior of hard metals and filled resins; FEM analysis of bulk and sheet forming processes
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Special Issue Information

Dear Colleagues,

I would like to call your attention to the Special Issue of Materials on Advanced Incremental Sheet Forming of Hard-to-Work Materials. Incremental sheet forming is being extensively used as an alternative technique in sheet-metal industry operations for the manufacture of components with symmetric and asymmetric shapes with the aid of CNC machines. This process initially developed for the needs of car body manufacturers, is now used by many other industries, i.e., automotive, aerospace, marine, and medical industries. In addition, due to its high flexibility, it is also considered a viable solution for reshaping sheet-metal end-of-life components in line with the principles of the circular economy. Recently, incremental sheet forming has been extended to hard-to-form metals, such as niobium, magnesium, titanium, and their alloys, and various thermoplastics, from high-crystalline to amorphous plastics, in order to overcome many typical issues of conventional and more innovative polymer-forming processes. Furthermore, the application of ISF has been extended to other materials, such as composites, due to the increasing necessity of the cost-efficient production of high-quality lightweight components.

The aim of this Special Issue is to present the latest achievements related to the characteristics, materials, and applications of incremental sheet forming of metal, polymer, and composite materials, in particular the hard-to-work materials. Research articles that focus on new developments in incremental sheet forming are welcome for consideration. I strongly believe that this Special Issue will reach the research community to enhance our collective understanding of the present status and trends of this flexible sheet forming process. Topics of interest include, but are not limited to, the following:

  • Description of new variants in the basic incremental forming process.
  • Investigation of the process parameters.
  • Evaluation of the workability of metal, polymer, and composite sheets.
  • Presentation of combined processes based on incremental sheet forming.
  • Process optimization strategies.
  • Modeling of the incremental forming processes.

Dr. Antonio Formisano
Guest Editor

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Keywords

  • incremental sheet forming
  • metals
  • polymers
  • composites
  • process parameters
  • process optimization
  • FEM analysis

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Published Papers (1 paper)

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Research

12 pages, 5075 KiB  
Article
Optimization of Single-Point Incremental Forming of Polymer Sheets through FEM
by Antonio Formisano, Luca Boccarusso and Massimo Durante
Materials 2023, 16(1), 451; https://doi.org/10.3390/ma16010451 - 3 Jan 2023
Cited by 10 | Viewed by 2849
Abstract
Incremental sheet forming represents a relatively new process appointed to form sheets of pure metals, alloys, polymers, and composites for the manufacture of components in fields where customized production in a short time and at a low cost is required. Its most common [...] Read more.
Incremental sheet forming represents a relatively new process appointed to form sheets of pure metals, alloys, polymers, and composites for the manufacture of components in fields where customized production in a short time and at a low cost is required. Its most common variant, named single-point incremental forming, is a flexible process using very simple tooling; the sheet is clamped along the edges and a hemispherical-headed tool follows a required path, to deform the sheet locally. In so doing, better formability is reached without any dedicated dies and for low-forming forces, which represent some of the attractive features of this process. Nevertheless, and with special reference to thermoplastic sheets, incremental formed parts suffer from peculiar defects like twisting and wrinkling. In this numerical work, analyses were conducted through a commercial finite element code by varying the toolpath strategy of the incremental forming of polycarbonate sheets. The investigation of some features like the forming forces, the deformation states, the energy levels, and the forming time was carried out, to determine the toolpath strategy able to optimize the incremental forming process of polymer sheets. The results of the numerical analyses highlight a reduction of the forming forces when using toolpaths alternating diagonal up and vertical down steps and, presumably, a reduced risk of failures and defects. Furthermore, these toolpath strategies solutions also have a positive impact on the environment in terms of energy and do not significantly increase the manufacturing time. Full article
(This article belongs to the Special Issue Advanced Incremental Sheet Forming of Hard-to-Work Materials)
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