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Subject: search.filters.subject.Single point incremental forming (SPIF)

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    A review on the effect of residual stresses in incremental sheet metal forming used in automotive and medical sectors
    (Elsevier, 2023) Kumar, Gulshan
    Incremental sheet forming (ISF) is a process that can produce sheet metal components with a series of stepwise small incremental deformation. This literature paper presents a thorough review of analyzing the influence of residual stresses in correlation with different process variables like tool diameter, tool path, the thickness of the sheet, depth of cut and wall angle, etc., during the procedure of single point incremental forming used in the automotive and medical industry. Moreover, this paper clearly explains the process parameters, which further help improve the ISF process compared to other conventional metal forming processes. This review initiates with the introduction of ISF for different types of materials and follows the residual stress measurement in various sectors. This paper also provides specific insights into the impact of residual stresses on forming forces, geometric shape accuracy, formability, and other factors in the process. The gap from this intensive review will provide the groundwork for the investigators for future research to recognize the implication of residual stresses in the automotive and medical fields. Based on the investigation, residual stresses should be considered in the design step of the manufacturing process with diverse scales. Finally, the future scope and probable research directions were discussed.
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    Residual stress analysis in titanium alloys used for biomedical application
    (Wiley, 2023-11) Kumar, Gulshan
    Biomedical applications like cranial plate, knee arthroplasty, ankle replacement, elbow and knee support braces, other orthopedic implants, and braces are required to be customized depending on the respective human body. These items can be made up of sheet metal. The slightest modification to the overall shape of sheet metal components leads to a reduction in production rate, raises costs, and impairs dimensional accuracy. Commercially pure titanium due to its excellent corrosion resistance, high formability properties, and high strength-to-weight ratio is considered to be an excellent material for a medical prosthesis. Single point incremental forming (SPIF), is an emerging technology that consists of a basic hemispherical tool, numerically monitored by a CNC machine that performs a progressing highly localized deformation. The poor dimensional accuracy would attribute to the development of residual stresses which may cause severe conditions for cranioplasty patients if the cranial plate is deformed. Even a small deformation due to residual stress may result in surgical replacement or even severe pain. Therefore, a better knowledge of the residual stresses is necessary to improve the geometrical precision of the process. The primary field of study is to thoroughly examine the surface residual stresses affected by the different process parameters of single-point incremental forming. In addition, microstructural behavior and forces induced during SPIF were also observed in relation to the strength of sheet metal.
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    Finite element analysis and experimental investigation in incremental sheet metal forming of composite matrix of Grade-V titanium
    (Springer, 2024-07) Kumar, Gulshan
    The single point incremental forming (SPIF) method is well-suited to meet the demands of the biomedical and aerospace sectors and a wide range of consumer preferences due to its notable attributes. The forming time and corrosion behaviour of the SPIF process using a composite matrix sheet of Ti-6Al-4 V were examined in this study. This paper also simulates a truncated conical, hemisphere, and hyperbolic geometry using finite element analysis and founds compressive residual stresses in a truncated conical shape. The effects of various process parameters, i.e. sheet thickness, tool diameter, spindle speed, step size, feed rate, and wall angle on these aspects were examined to optimize parameter levels to achieve the lowest forming time with the aid of the design of experiments (DOE) using Taguchi analysis. The tool diameter, sheet thickness, and incremental depth are the three most significant parameters that have the most effects on the forming time, according to the analysis’s results. The forming time is predicted using an artificial neural network (ANN). ANN anticipates the forming time with 98% accuracy. A salt spray tester was used in the present study for the observation of corrosion behaviour at different time intervals. It was found that there was no white rust or no red rust after multiple intervals. Based on the corrosion behaviour shown in this study, it can be suggested that composite matrix grade-V titanium sheet material is suitable for biomedical and aerospace applications.