Comprehensive Study on Enhancing the Forming Performance of Incrementally Forming Sheet Metal
Keywords:
Customized Heat Treatment, Die-less Manufacturing, Incremental Sheet Forming, Process Optimization, Predictive ModelingAbstract
Incremental sheet forming (ISF) is a versatile, die‐less sheet metal forming process that allows for the manufacture of complex shapes in sheet metals at minimal tooling expense. Its widespread application, however, is hindered by significant limitations such as high forming forces, rapid work hardening, and unfavorable surface finish, especially for challenging-to-beat alloys like stainless steel, high-strength aluminum, and titanium. This review presents recent advances to enhance sheet metal formability. We examine innovative heat-assisted methods, such as local approaches (e.g., laser- and electrical-assisted forming) that accurately soften the deformation zone, and global strategies (e.g., hot air and oil bath heating) that evenly improve ductility, and hybrid strategies with ultrasonic vibrations. The role of hybrid approaches that integrate two or more heating methods to find an optimal balance between energy efficiency and properties of materials is investigated. The impact of significant process factors (temperature, tool geometry, tool rotation, feed rate, and step size) is thoroughly analyzed, and predictive modeling methods (analytical, numerical, and empirical) are presented to formulate robust optimization algorithms. Scalability of the ISF process in industry, considering its applications in aerospace, automotive, and biomedical industries, is also included under the review. This comprehensive study outlines current challenges and proposes avenues for future research to advance incremental sheet forming further towards more efficient, sustainable, and reliable industrial applications.
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