Article
Engineering, Manufacturing
Sandeep Pandre, Ayush Morchhale, Nitin Kotkunde, Suresh Kurra
Summary: This study investigates the incremental forming behavior using different parameters and validates the fracture forming limits, limiting wall angle, and form accuracy through experiments and numerical simulations. Error compensation method is utilized to enhance the accuracy of the formed components.
MATERIALS AND MANUFACTURING PROCESSES
(2021)
Article
Engineering, Manufacturing
Hosein Khalatbari, Ismail Lazoglu
Summary: This study addresses the issue of low formability of Polyoxymethylene (POM) in incremental sheet forming (ISF) by introducing friction-induced heat at the tool-sheet interface to improve the sheet formability. Through experimental and analytical methods, the study investigates the formability of POM and calculates the force, friction-induced heat, and temperature at the tool-sheet interface based on the Johnson-Cook plasticity model and Finite Difference Method.
MATERIALS AND MANUFACTURING PROCESSES
(2021)
Article
Engineering, Mechanical
Fabio Andre Lora, Daniel Fritzen, Ricardo Alves de Sousa, Lirio Schaffer
Summary: This work assesses the potential of combining conventional and incremental sheet forming processes in a same sheet of metal, with the results showing that pre-forming has a direct influence on strain paths and proper pre-strain can enhance the formability of incremental sheet forming.
CHINESE JOURNAL OF MECHANICAL ENGINEERING
(2021)
Article
Materials Science, Multidisciplinary
Praveen Kumar Gandla, Sandeep Pandre, Kurra Suresh, Nitin Kotkunde
Summary: This study investigates the effect of different forming strategies on material flow in incremental forming of hemispherical dome shaped components. It was found that multistage forming strategies successfully overcome the limitations of single stage forming, with intermediate shapes significantly impacting forming limits, geometric accuracy, and manufacturing time. Additionally, a new theoretical model based on volume consistency approach was proposed to predict sheet thickness during multi-stage forming.Finite element simulations showed good agreement with experimental results, validating the quality parameters obtained from the study.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2022)
Article
Engineering, Industrial
Xuelei Zhao, Hengan Ou
Summary: This research introduces a new flexible multi-point incremental sheet forming process with multi-layer sheets (F-MPIF-MLS). The novelty of this process lies in the development of a new flexible multi-point die system and the use of multi-layer sheets, which overcome the limitations of excessive sheet thinning and poor surface finish in the conventional MPIF process. Experimental testing and FE simulation are conducted to compare the new F-MPIF-MLS with the conventional MPIF processes, showing a reduction in wrinkling and a more uniform thickness distribution in the formed part using the new flexible multi-point die system with multi-layer sheets.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2023)
Article
Engineering, Multidisciplinary
G. Hussain, Malik Hassan, Hongyu Wei, J. Buhl, Maohua Xiao, Asif Iqbal, Hamza Qayyum, Asim Ahmed Riaz, Riaz Muhammad, Kostya (Ken) Ostrikov
Summary: Single Point Incremental Forming (SPIF) is an emerging materials processing technology that has gained growing interest in the application of composite materials due to its advantages such as reduced tooling, cycle time, cost, and ability to produce sculptured profiles compared to traditional methods. This authoritative article reviews the advancements in SPIF since 2008, covering various aspects of the process including deformation characteristics, forming limits, failure modes, forming forces, strain recovery, surface quality, and analytical models. It reveals the current state of the technology, challenges, and provides valuable findings that serve as guidelines for the process users.
ALEXANDRIA ENGINEERING JOURNAL
(2023)
Article
Materials Science, Multidisciplinary
Mateus Dobecki, Alexander Poeche, Walter Reimers
Summary: This study presents experimental evidence of the forming mechanisms shear, bending, and stretching in single-point incremental forming through high-energy synchrotron x-ray diffraction. The depth-resolved texture evolution offers insights into the forming mechanisms acting in SPIF, with adjusting step-down increments triggering the forming mechanisms explicitly. Controlling the residual stress states by optimizing process parameters necessitates knowledge of the fundamental forming mechanism action.
METALLURGICAL AND MATERIALS TRANSACTIONS A-PHYSICAL METALLURGY AND MATERIALS SCIENCE
(2021)
Article
Automation & Control Systems
Mohanraj Murugesan, Hyung-Won Youn, Jae-Hyeong Yu, Wanjin Chung, Chang-Whan Lee
Summary: The present study evaluates the benefits of adding vacuum to the conventional ISF process for limiting the pillow effect and studies the impact of forming parameters on pillowing. The results show that the forming tool diameter is the most important parameter affecting pillowing, and vacuum presence greatly reduces material pillowing. Furthermore, vacuum uniformly deforms materials and controls shear deformation by balancing local element strain accumulation, but when the tool diameter increases, the produced parts have no shear deformation.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Aerospace
Sattar Ullah, Xiaoqiang LI, Peng Xu, Yanle LI, Kai Han, Dongsheng LI
Summary: The double-sided incremental forming (DSIF) process improves process flexibility but faces geometric precision challenges. Two strategies are proposed to overcome the challenges: determining the optimal support tool location and using a two-stage process. The results show that the proposed method outperforms other toolpath strategies in terms of geometric accuracy, surface roughness, forming time, and sheet thickness fluctuations.
CHINESE JOURNAL OF AERONAUTICS
(2023)
Review
Materials Science, Multidisciplinary
Tomasz Trzepiecinski, Valentin Oleksik, Tomaz Pepelnjak, Sherwan Mohammed Najm, Imre Paniti, Kuntal Maji
Summary: Lightweight materials like titanium alloys, magnesium alloys, and aluminum alloys offer high strength, corrosion resistance, and low weight, but may have limitations in formability. This article reviews the state-of-the-art methods of incremental sheet forming (ISF) for lightweight materials from 2015 to 2021, focusing on the effects of different ISF variants on surface finish, geometric accuracy, and process formability of sheet metals.
Review
Engineering, Manufacturing
Ashish Gohil, Bharat Modi
Summary: Incremental sheet forming process has attracted researchers' interest in the field of sheet metal forming due to its high formability and capability to produce prototypes of new products at low cost. Current research is focused on enhancing the process capabilities for potential commercial production. This article reviews the progress and recent developments in incremental forming, summarizes the impact of various process parameters on performance, and discusses unresolved issues for further attention.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE
(2021)
Article
Chemistry, Analytical
Vytautas Ostasevicius, Darius Eidukynas, Vytautas Jurenas, Ieva Paleviciute, Marius Gudauskis, Valdas Grigaliunas
Summary: This study aims to evaluate the feasibility of producing small-batch polymer sheet components inexpensively using robotized single point incremental forming (SPIF) without backing plate support. An innovative method involving thermal and ultrasound assisted deformation of polymer sheets was proposed, increasing plasticity and production efficiency.
Article
Materials Science, Multidisciplinary
K. Ramkumar, M. Varatharajulu, C. B. Priya, V. Vijayan
Summary: This study investigates the suitable input parameters for grade 316 stainless steel, a material widely used in both domestic and industrial applications. Various output measurements, such as wall angle, formability, surface finish, and spring back, were obtained through experimental investigation. Optimized input parameters were determined using grey relational analysis (GRA) and technique for order preference by similarity to ideal solution method (TOPSIS). Analysis of variance (ANOVA) was used to identify the most influential factor.
Article
Engineering, Mechanical
Sandeep Pandre, Gandla Praveen Kumar, Nitin Kotkunde, Kurra Suresh, Swadesh Kumar Singh
Summary: Experimental and numerical investigations were conducted on an automotive-grade DP steel to study its formability parameters during incremental sheet forming at different temperatures. The results showed that the fracture limits of the material formed at 400 degrees C were 14.06% higher than those formed at room temperature. The study also validated the forming forces, thickness distribution, and geometrical accuracy through experimental and FE simulations.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART E-JOURNAL OF PROCESS MECHANICAL ENGINEERING
(2022)
Article
Automation & Control Systems
Narinder Kumar, Rakesh Lingam, Anupam Agrawal
Summary: This study aims to overcome the issue of excessive thinning in single point incremental forming process when forming parts at steep wall angles. By employing an improved clamping mechanism and a multi-stage forming approach, the thickness distribution can be improved, resulting in better quality of formed components.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Green & Sustainable Science & Technology
Jose M. D. Correia, Gabriel F. Serra, Ricardo Alves J. de Sousa, Antonio B. Pereira, Fabio A. O. Fernandes
Summary: This paper focuses on utilizing expanded cork-based composite to produce surfboards, and evaluates its mechanical properties through experiments and numerical models. The results show that expanded cork performs well in sandwich composite structures, providing substantial load-bearing capacity while reducing weight and environmental impact.
Article
Chemistry, Multidisciplinary
Pedro O. Santos, Gustavo P. Carmo, Ricardo J. Alves de Sousa, Fabio A. O. Fernandes, Mariusz Ptak
Summary: This study aimed to develop a cranial implant and study its mechanical performance by integrating it into a finite element model. The results showed that the model with eight fixation screws performed better in terms of stress and displacement, and under specific conditions, the implant offered better brain protection compared to the integral skull.
APPLIED SCIENCES-BASEL
(2022)
Article
Metallurgy & Metallurgical Engineering
Mehdi Safari, Ricardo Alves de Sousa, Jalal Joudaki
Summary: In this study, the bending of mild steel tubes was investigated using a laser beam. The effects of six process parameters on the bending angles were examined. The results showed that increasing laser power, irradiation length, and number of irradiation passes, as well as reducing scanning speed and laser beam diameter, led to higher bending angles.
STEEL RESEARCH INTERNATIONAL
(2023)
Article
Education & Educational Research
Amar Kumar Behera, Ricardo Alves de Sousa, Valentin Oleksik, Jingyan Dong, Daniel Fritzen
Summary: This study captures student perceptions of the effectiveness of remote learning and assessment in two associated engineering disciplines, mechanical and industrial, during the COVID-19 pandemic in a cross-national study. A structured questionnaire was used to analyze student preferences and the results showed a strong preference for face-to-face teaching, especially in laboratory courses. In addition, students preferred remote live lectures over recorded ones. However, concerns were raised about group work and communication during remote learning.
EUROPEAN JOURNAL OF ENGINEERING EDUCATION
(2023)
Article
Mechanics
Gabriel Ferreira Serra, Fabio A. O. Fernandes, Ricardo J. Alves de Sousa, Eduardo Noronha, Mariusz Ptak
Summary: This study investigates the impact resistance of hybrid composites with cork laminates and other materials. The results show that a solution with encapsulated STF can significantly reduce peak acceleration and provide smoother deceleration, while a solution with impregnated fabric is lightweight and has good impact resistance.
COMPOSITE STRUCTURES
(2022)
Article
Materials Science, Multidisciplinary
Mehdi Safari, Seyed Mohammad Miralaa, Ricardo Alves de Sousa
Summary: This work experimentally studies the laser forming process of cylindrical surfaces. The effects of process parameters such as laser power, laser scanning scheme, and distance between irradiation lines on the radius of curvature of the laser-formed cylindrical surfaces are examined. The design of experiment (DOE) method based on the Box-Behnken algorithm is employed for investigations. Results indicate that increasing laser power decreases the radius of curvature of a laser-formed cylindrical surface. Additionally, the radius of curvature of the cylindrical surface increases with increasing scanning speed, while it decreases with increasing distance between irradiation lines.
Article
Materials Science, Multidisciplinary
Jaques Araripe Suris, Charles Chemale Yurgel, Ricardo Alves de Sousa
Summary: The hot forging process improves the mechanical properties of parts compared with casting or machining. Metal flow in forging leads to texture changes known as grain-flow orientation (GFO). This study investigated the influence of GFO on fatigue life using a rotational flexing fatigue test. Experimental results showed that forged samples with GFO in the main deformation direction exhibited higher fatigue life compared to other configurations.
Review
Biology
Gustavo P. Carmo, Jeroen Grigioni, Fabio A. O. Fernandes, Ricardo J. Alves de Sousa
Summary: This article aims to provide readers with a concise description of the main contributions in the field of traumatic brain injuries and neurodegenerative outcomes for women, especially related to chronic traumatic encephalopathy. It also reviews the numerical models created to address these issues and discusses the use (or lack of use) of sex-specific validation experiments. The article highlights the importance of considering sex differences in both direct injuries and the conditions that precede and follow traumatic events.
Article
Computer Science, Interdisciplinary Applications
Gustavo P. Carmo, Mateusz Dymek, Mariusz Ptak, Ricardo J. Alves-de-Sousa, Fabio A. O. Fernandes
Summary: Traumatic brain injuries are a major cause of death and disability worldwide. Finite element head models have been developed to understand the forces and interactions in the human head, offering a cost-effective and ethical alternative to experimental tests. The female finite element head model (FeFEHM) can provide insights into injury mechanisms and neurodegenerative diseases.
COMPUTER METHODS AND PROGRAMS IN BIOMEDICINE
(2023)
Article
Engineering, Biomedical
Afonso J. C. Silva, Ricardo J. Alves de Sousa, Fabio A. O. Fernandes, Mariusz Ptak, Mateusz Dymek, Marco P. L. Parente
Summary: The aim of this research is to create a finite element model that accurately represents the female cervical spine in order to better understand its mechanics and develop treatments or preventative measures. This study builds upon a previous research where a model was created from CT scans of a 46-year-old female and simulated a functioning spinal unit for validation. The reduced model was validated using experimental data from cadaveric specimens assessing the range of motion of different cervical segments in various movements.
JOURNAL OF THE MECHANICAL BEHAVIOR OF BIOMEDICAL MATERIALS
(2023)
Article
Chemistry, Physical
Maria Kuranska, Mariusz Ptak, Elzbieta Malewska, Aleksander Prociak, Mateusz Barczewski, Mateusz Dymek, Fabio A. O. Fernandes, Ricardo Alves de Sousa, Krzysztof Polaczek, Karolina Studniarz, Katarzyna Uram
Summary: Renewable materials are naturally replenished and can be reused materials, such as bamboo, cork, hemp, and recycled plastic. Using renewable components reduces dependence on petrochemical resources and waste. Adopting these materials in various industries can lead to a more sustainable future and decrease the carbon footprint.
Article
Chemistry, Physical
Nicolae Rosca, Mihaela Oleksik, Liviu Rosca, Eugen Avrigean, Tomasz Trzepiecinski, Sherwan Mohammed Najm, Valentin Oleksik
Summary: Polymeric materials are being increasingly used in various industries due to their advantages of providing good mechanical strength at low weight. The incremental forming process for polymeric materials is becoming more important because of its ability to produce complex parts at minimum cost without the need for expensive dies. The study focuses on understanding the main strains and thickness reduction during the process and utilizes the Taguchi method for experimental design.
Article
Materials Science, Multidisciplinary
Nijenthan Rajendran, Charles Chemale Yurgel, Wojciech Z. Z. Misiolek, Ricardo Alves de Sousa
Summary: The study focuses on developing a new forging process for a wind turbine pinion shaft, using Deform 3D software for near-net-shape forming. The Finite Element Method is used to create a process model for the existing hot forging process, and new die designs are proposed based on simulation results and compared to the actual process. The new designs show improvements in terms of cavity filling and grain flow orientation.
