Handbook of Flexible and Smart Sheet Forming Techniques E-Book

• Herausgeber: John Wiley & Sons
• Kategorie: Fachliteratur
• Sprache: Englisch

Veröffentlichungsjahr: 2023

Beschreibung

HANDBOOK OF FLEXIBLE AND SMART SHEET FORMING TECHNIQUES

Single-source guide to innovative sheet forming techniques and applications, featuring contributions from a range of engineering perspectives

Handbook of Flexible and Smart Sheet Forming Techniques presents a collection of research on state-of-art techniques developed specifically for flexible and smart sheet forming, with a focus on using analytical strategies and computational, simulation, and AI approaches to develop innovative sheet forming techniques. Bringing together various engineering perspectives, the book emphasizes how these manufacturing techniques intersect with Industry 4.0 technologies for applications in the mechanical, automobile, industrial, aerospace, and medical industries.

Research outcomes, illustrations, case studies, and examples are included throughout the text, and are useful for readers who wish to better understand and utilize these new manufacturing technologies.

Topics covered in the book include:

• Concepts, classifications, variants, process cycles, and materials for flexible and smart sheet forming techniques
• Comparisons between the aforementioned techniques and other conventional sheet forming processes, plus hardware and software requirements for these techniques
• Parameters, responses, and optimization strategies, mechanics of flexible and smart sheet forming, simulation approaches, and future innovations and directions
• Recent advancements in the field, including various optimizations like artificial intelligence, Internet of Things, and machine learning techniques

Handbook of Flexible and Smart Sheet Forming Techniques is an ideal reference guide for academic researchers and industrial engineers in the fields of incremental sheet forming. It also serves as an excellent comprehensive reference source for university students and practitioners in the mechanical, production, industrial, computer science engineering, medical, and pharmaceutical industries.

Leseprobe

Table of Contents

Cover

Table of Contents

Title Page

Copyright Page

About the Editors

List of Contributors

Preface

1 Incremental Sheet Forming – A State‐of‐Art Review

1.1 Introduction to Incremental Sheet Forming

1.2 Incremental Sheet Forming Process

1.3 Materials for Incremental Sheet Forming

1.4 Formability Limits with AI Implementation

1.5 Conclusions and Future Scope

References

2 Classification of Incremental Sheet Forming

2.1 Introduction

2.2 Classification of ISF

2.3 Conclusion

2.4 Future Work

References

3 A Review on Effect of Computer‐Aided Machining Parameters in Incremental Sheet Forming

3.1 Introduction

3.2 Process Parameters

3.3 Conclusion

3.4 Future Work

Funding Statement

Conflicts of Interest

Acknowledgment

References

4 Equipment and Operative for Industrializing the SPIF of Ti‐6Al‐4V

4.1 Introduction

4.2 Materials and Methods

4.3 Results and Discussion

4.4 Conclusion

References

5 Texture Development During Incremental Sheet Forming (ISF): A State‐of‐the‐Art Review

5.1 Introduction

5.2 Crystallographic Texture

5.3 Microstructure Evolution During ISF

5.4 Deformation Mechanism During ISF

5.5 Future Scope

5.6 Summary

Abbreviations

References

6 Analyses of Stress and Forces in Single‐Point Incremental Sheet Metal Forming

6.1 Introduction

6.2 Experimental Setup

6.3 FE Analysis of ISF

6.4 Conclusion

6.5 Future work

References

7 Finite Element Simulation Approach in Incremental Sheet Forming Process

7.1 Introduction

7.2 Finite Element Simulation

7.3 Conclusion

References

8 Detection of Defect in Sheet Metal Industry: An Implication of Fault Tree Analysis

8.1 Introduction

8.2 Methodology

8.3 Result and Analysis

8.4 Discussion

8.5 Conclusion

References

9 Integration of IoT, Fog‐ and Cloud‐Based Computing‐Oriented Communication Protocols in Smart Sheet Forming

9.1 Introduction

9.2 Background

9.3 Communication Protocol Overview

9.4 Comparative Study of Communication Protocol for IoT Premise

9.5 IOT, FOG, and CLOUD (ITCFBC) Are Interrelated

9.6 Challenges and Related Issues

9.7 Conclusion and Future Scope

References

10 Blockchain for the Internet of Things and Industry 4.0 Application

10.1 Introduction

10.2 Blockchain's Application in a Wide Range of Industries

10.3 Blockchain Plays in the Future of Our Economy

10.4 Changes in Society Using the Internet of Things and Blockchain

10.5 Blockchain Transform Industries and the Economy

10.6 Blockchain Support Swinburne's Industry 4.0 Strategy

10.7 Blockchain Technology's Impact on the Digital Economy

10.8 Chains Are Being Revolutionized by Blockchain Technology

10.9 Businesses That Use Blockchain Technology

10.10 Real‐World Use Cases for dApps and Smart Contracts

10.11 Blockchain Is About to Revolutionize the Courtroom

10.12 Conclusion

References

11 Experimental Study on the Fabrication of Plain Weave Copper Strips Mesh‐Embedded Hybrid Composite and Its Benefits Over Traditional Sheet Metal

11.1 Introduction

11.2 Proposed Methodology

11.3 Experimental Procedure

11.4 Results and Discussions

11.5 Conclusions

11.6 Future Scope

References

12 Application of Reconfigurable System Thinking in Reconfigurable Bending Machine and Assembly Systems

12.1 Introduction: Background and Overview

12.2 Description of Machining, Bending, and Assembly Processes

12.3 Related Works on Manufacturing Systems

12.4 Conventional Sheet Metal Bending and Assembly System Technologies

12.5 Trends and Evolution of Manufacturing System Paradigms

12.6 Case Studies for Application of RMS in Bending Operations

12.7 Scalability Planning for RMS

12.8 Modularity Assessment for Reconfigurable Systems

12.9 Case Studies for Application of RMS in Assembly Operations

12.10 Conclusions

References

13 Application of Incremental Sheet Forming (ISF) Toward Biomedical and Medical Implants

13.1 Introduction

13.2 Classification of ISF

13.3 Process Parameters of ISF

13.4 Materials for Fabrication of Implants

13.5 Methods of Implant Manufacturing

13.6 Applications of ISF Process

13.7 Challenges of ISF Process

13.8 Future Scope of ISF

13.9 Conclusion

References

Index

End User License Agreement

List of Tables

Chapter 1

Table 1.1 Various heating strategies and sources in thermal‐assisted increme...

Chapter 2

Table 2.1 Application of ISF.

Chapter 3

Table 3.1 Application of ISF.

Table 3.2 Review of process parameters on surface roughness.

Table 3.3 Review of process parameters on forming force.

Table 3.4 Review of process parameters on formability.

Table 3.5 Review of process parameters on thickness distribution.

Table 3.6 Review of process parameters on dimensional accuracy.

Table 3.7 Review of process parameters on energy consumption.

Chapter 4

Table 4.1 Main characteristics of the initial heating chamber.

Table 4.2 Properties of the forming tool ceramic.

Table 4.3 Maximum wall angle tests.

Table 4.4 Sheet temperature measurements with furnace at 900 °C.

Table 4.5 Hot SPIF tests at different temperatures.

Table 4.6 Representative deviations values of parts produced at different te...

Table 4.7 Comparative of the geometric deviation figures obtained forming at...

Table 4.8 Deviation maps statistics of test D2 (forming at 675 °C) iteration...

Chapter 5

Table 5.1 Forming parameters and sample nomenclature used in the present inv...

Table 5.2 Average grain size and misorientation fraction.

Chapter 6

Table 6.1 Table of process parameters for the experiment.

Chapter 7

Table 7.1 Commonly available finite element analysis (FEA) software used in ...

Chapter 8

Table 8.1 Reported manufacturing defect.

Table 8.2 Problem description.

Table 8.3 Risk priority number calculation.

Chapter 9

Table 9.1 Application layer‐based protocols‐key characteristics.

Table 9.2 Comparative study of communication protocol.

Chapter 11

Table 11.1 Composition of E‐glass fiber.

Table 11.2 Properties of epoxy resin (Araldite LY556).

Table 11.3 Properties of hardener (ARADUR HY951).

Table 11.4 Theoretical and actual weight percentage of different raw materia...

Table 11.5 Nomenclature and brief details of prepared samples.

Table 11.6 Experimental values and results for tensile strength of composite...

Table 11.7 Experimental values and results for flexural strength of composit...

Table 11.8 Experimental values and results for Izod impact strength of compo...

Table 11.9 Experimental values and results for Shore D hardness of composite...

Table 11.10 Experimental values and results for density of composites.

Chapter 12

Table 12.1 Reconfigurability needs for the RBPT.

Table 12.2 Evaluation of RMS principles of RBPM machine.

Table 12.3 Scalability planning for the RBPM machine for different part geomet...

Table 12.4 Configuration convertibility for RBPM machine.

Table 12.5 Modularity assessment for the RBPM machine for different part geo...

Table 12.6 Evaluation of RMS principles of RAF machine.

Chapter 13

Table 13.1 Materials used in incremental sheet forming.

List of Illustrations

Chapter 1

Figure 1.1 Impact of incremental sheet forming with Industry 4.0 technologie...

Figure 1.2 Representation of wall angle “

α

”.

Figure 1.3 (a) Single‐stage incremental sheet forming. (b) Multistage increm...

Figure 1.4 Single‐point incremental sheet forming (SPISF).

Figure 1.5 Two‐point incremental sheet forming (TPISF).

Figure 1.6 TPISF with partial die (left) and TPISF with full die (right)....

Figure 1.7 DSISF method before (left) and after (right) simultaneous working...

Chapter 2

Figure 2.1 Basic steps in ISF.

Figure 2.2 Classifications of incremental sheet forming.

Figure 2.3 SPIF using CNC milling machine.

Figure 2.4 Classification of two‐point incremental sheet forming.

Figure 2.5 TPIF using (a) auxiliary tool (b) Partial die (c) Specific die.

Figure 2.6 Classification based on forming tool of ISF.

Figure 2.7 (a) Flat end tool, (b) Hemispherical tip tool, (c) Rolling ball t...

Figure 2.8 Classification based forming paths of ISF.

Figure 2.9 Different tool paths and tool directions (a) profile tool path an...

Figure 2.10 Classification based on forming machine of ISF.

Figure 2.11 Classifications based hot‐forming of ISF.

Chapter 3

Figure 3.1 Cause and effect diagram of process parameter and performance par...

Figure 3.2 Different tool paths, tool directions and tool geometries: (a) pr...

Figure 3.3 Forming force with respect to time in different zones [31, 32, 37...

Figure 3.4 Sample curve plot (a) FLD and FFLD, (b) PEPS‐FLD and PEPS‐FFLD, a...

Figure 3.5 Thickness variation after SPIF of truncated cone from center (lef...

Figure 3.6 Dimensional error in incremental sheet forming.

Figure 3.7 Time share for different production mode.

Figure 3.8 Time share for different production mode.

Figure 3.9 Energy breakdown in to subunits.

Chapter 4

Figure 4.1 Initial heating chamber.

Figure 4.2 Clamping frame fixing the sheet on the top of the chamber cavity....

Figure 4.3 Ti grade 2 sheets cold forming with a punch type tool (left) and ...

Figure 4.4 Spinning type forming tool initially used.

Figure 4.5 Aspects and methods for achieving the SPIF of Ti‐6Al‐4V.

Figure 4.6 Varying angle geometry to identify the maximum wall angle.

Figure 4.7 Global heating concept for hot SPIF.

Figure 4.8 Heater frame (left) and integration in the furnace (right).

Figure 4.9 Temperature control points and sensors selected for the heating s...

Figure 4.10 Temperature control points and sensors along the three operation...

Figure 4.11 Commanded temperature evolution at furnace and sheet: with ON–OF...

Figure 4.12 Heating system saturation temperature.

Figure 4.13 System heating up to 540 °C: entire cycle (left) and detail at t...

Figure 4.14 System heating up to 650 °C: entire cycle (left) and detail at t...

Figure 4.15 System cooling down from 700 °C through 500 °C.

Figure 4.16 Distribution of the temperature on the sheet surface at 540 °C: ...

Figure 4.17 Distribution of the temperature on the sheet surface at 700 °C: ...

Figure 4.18 Wheel axis temperature during forming at 650 °C.

Figure 4.19 Original ceramics design: calculated load distribution (left) an...

Figure 4.20 New forming tool: conceptual design (left), ceramics detail (top...

Figure 4.21 Inner of the new tool after one forming test.

Figure 4.22 Costs incurred in conventional technologies and hot SPIF.

Figure 4.23 Scale effect comparison of hot conventional technologies vs SPIF...

Figure 4.24 Sequences to fabricate a part made of Ti‐6Al‐4V by hot SPIF.

Figure 4.25 Geometry deviations in parts formed at different temperatures: 5...

Figure 4.26 Deviation maps of test D2 (forming at 675 °C) iterations.

Figure 4.27 Deviations in the perimeter of a Ti‐6Al‐4V part fabricated witho...

Figure 4.28 Identification of the part depth affected by deflection by means...

Figure 4.29 CAD geometry redesign including addendum.

Figure 4.30 Map of deviations of parts produced with addendum: (a) Compariso...

Figure 4.31 Deviation profile of a section A extracted from a deviation map ...

Figure 4.32 Straight cut in Ti‐6Al‐4V part manufactured at 900 °C in the fur...

Figure 4.33 Trimming of samples on parts produced at furnace temperatures of...

Figure 4.34 Residual stresses: (a) Scheme of the measurements made on the va...

Figure 4.35 Cross‐shaped samples taken from manufactured parts with differen...

Figure 4.36 Deviation maps and results table of cross‐cut samples/Fit betwee...

Figure 4.37 Ti‐6Al‐4V part surface after the hot SPIF process: inner face (l...

Figure 4.38 Decontaminated part: before trimming (left), and after trimming ...

Figure 4.39 Map of part deviations: before (left) and after finishing operat...

Figure 4.40 Comparison before and after the finishing operations.

Chapter 5

Figure 5.1 Schematic representation of sheet of polycrystalline material wit...

Figure 5.2 Formed component and sample locations used in EBSD and bulk textu...

Figure 5.3 ODFs at different φ

2

sections for (a) as‐received, (b) ST, (c) SM...

Figure 5.4 Volume fraction of different texture components.

Figure 5.5 (a) Geometric models and (b) formed parts subjected to early, int...

Figure 5.6 Experimental X‐ray pole figures and ϕ2 sections of the ODFs in Eu...

Figure 5.7 Volume fractions (Vf) of different texture components resulting w...

Figure 5.8 EBSD Inverse pole figure maps of (a) sample 1 (b) sample 2 (c) sa...

Figure 5.9 KAM distribution and average KAM of (a) starting sample (b) sampl...

Figure 5.10 (a), (c), and (e) Inverse pole figure and (b), (d), and (f) IQ m...

Figure 5.11 Instantaneous deformation zone and contact area between forming ...

Figure 5.12 Rotational symmetric single‐point incremental forming: (a) schem...

Chapter 6

Figure 6.1 Types of incremental sheet forming process.

Figure 6.2 Experimental setup.

Figure 6.3 Tool path strategy with constant

Z

.

Figure 6.4 Tool path strategy with a constant

Z

spiral.

Figure 6.5 ISF experimental components.

Figure 6.6 Tool path trajectory point frustum of (a) pyramid and (b) cone.

Figure 6.7 Von Mises stresses for (a) frustum of pyramid and (b) frustum of ...

Figure 6.8 Variation of contact area between semispherical end tool and shee...

Figure 6.9 (a) The resultant force acting on the frustum of a pyramid. (b) T...

Figure 6.10 Thinning variations percentage (a) frustum of pyramid and (b) fr...

Chapter 7

Figure 7.1 Flowchart showing MBS model.

Figure 7.2 Transitional changes of MBS into FEM.

Figure 7.3 Categories of finite element simulation.

Figure 7.4 FEM model of ISF process.

Chapter 8

Figure 8.1 Sheet metal defect detection by fault tree analysis.

Figure 8.2 Fishbone diagram.

Figure 8.3 Pareto chart analysis.

Chapter 9

Figure 9.1 Ecosystem having blend among ITCFBC.

Figure 9.2 Models of (a) Req.‐Rep. and (b) Pub.‐Sub. (RRPSM).

Figure 9.3 Role of AP (Application protocols) in fusion of ITCFBC networks....

Chapter 11

Figure 11.1 Orientation of fibers based composite classification.

Figure 11.2 Matrix based composite classification.

Figure 11.3 Reinforcements based composite classification.

Figure 11.4 Methodology proposed for the present work.

Figure 11.5 E‐Glass Fiber or Fiberglass (CSM).

Figure 11.6 Epoxy resin (Araldite LY556) and Hardener (Aradur HY951).

Figure 11.7 Flat copper sheet (35 gauge).

Figure 11.8 (a) and (b) Molds.

Figure 11.9 Plain weave copper strips mesh preparation (a) Copper strips and...

Figure 11.10 Plain weave copper strips mesh.

Figure 11.11 Mold with layers of releasing agents.

Figure 11.12 Measurement of weight of (a) fiberglass and (b) epoxy resin.

Figure 11.13 Electronic balance.

Figure 11.14 Preheating of epoxy resin mix.

Figure 11.15 Spreading of epoxy resin mix with a brush.

Figure 11.16 (a) Making of GFRP Composite and (b) Addition of plain weave co...

Figure 11.17 (a) Pressure applying by washer roller and (b) Placing top laye...

Figure 11.18 (a) De‐molding from the top, (b) Completely de‐molded from the ...

Figure 11.19 (a) GFRP composite laminate and (b) Hybrid composite laminate....

Figure 11.20 Cross‐section view of hybrid composite.

Figure 11.21 Tensile strength testing (a) GFRP composite and (b) Hybrid comp...

Figure 11.22 Tensile strength test samples.

Figure 11.23 Flexural strength testing (a) GFRP composite and (b) Hybrid com...

Figure 11.24 Flexural strength test samples.

Figure 11.25 Impact strength testing (a) GFRP composite and (b) Hybrid compo...

Figure 11.26 Impact strength test samples.

Figure 11.27 Hardness testing.

Figure 11.28 Hardness and density test samples.

Figure 11.29 Mass of samples for density calculation (a) GFRP composite and ...

Figure 11.30 Samples after testing.

Figure 11.31 Load v/s displacement graph of hybrid composite.

Figure 11.32 Comparison of tensile strength of both composites.

Figure 11.33 Comparison of flexural strength of both composites.

Figure 11.34 Comparison of breaking energy of both composites.

Figure 11.35 Comparison of impact strength of both composites.

Figure 11.36 Comparison of hardness of both composites.

Figure 11.37 Comparison of density of both composites.

Chapter 12

Figure 12.1 (a) Machining, (b) Bending and (c) Assembly operations.

Figure 12.2 (a) drilling operation (b) peripheral and (c) face milling (d) t...

Figure 12.3 Types of press brake frames.

Figure 12.4 Classification of press brake based on structural frame model an...

Figure 12.5 Classification of press brake machines.

Figure 12.6 Robotic sheet metal feeder of press brake.

Figure 12.7 Press brake machines in tandem.

Figure 12.8 Classification of assembly systems [13].

Figure 12.9 Third length configuration‐ (with two split side halves and two ...

Figure 12.10 Subtraction and addition of modules on the RBPM machine.

Figure 12.11 Tool library for sheet metal bending press machines.

Figure 12.12 Assessment tree analysis for RBPM machine convertibility.

Figure 12.13 Common machine module relationship.

Figure 12.14 Part‐Module relationship various shared sheet metal part featur...

Figure 12.15 Machine‐part relationships for press brake machine.

Figure 12.16 Process plan‐part relationships for press brake machine.

Figure 12.17 Common features in product family.

Figure 12.18 Reconfigurable assembly fixture concept.

Figure 12.19 Subtraction and addition of modules on the RBPM machine.

Figure 12.20 Module library for reconfigurable assembly fixture.

Figure 12.21 Integration of module to assemble various part families of pres...

Chapter 13

Figure 13.1 Various processes of manufacturing: (a) Milling process [5], (b)...

Figure 13.2 SPIF principle presented by Iseki et al. [13].

Figure 13.3 Single‐point incremental forming.

Figure 13.4 Two‐point incremental forming.

Figure 13.5 Steps for fabrication of cranioplasty plates [37].

Figure 13.6 Cranial fracture (left) and prosthesis (right).

Figure 13.7 CAD model of prosthesis [15].

Figure 13.8 Methodology for manufacturing a customized cranial implant by IS...

Figure 13.9 Simplified model of the facial implant produced by SPIF: (a) geo...

Figure 13.10 The scheme of the SPIF process.

Figure 13.11 Current (traditional) surgical methodology of implementation of...

Figure 13.12 Standard designs of Unicondylar knee Arthroplasty.

Figure 13.13 Future scope and potential research directions for the novel fo...

Guide

Cover Page

Title Page

Copyright Page

About the Editors

List of Contributors

Preface

Table of Contents

Begin Reading

Index

WILEY END USER LICENSE AGREEMENT

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Handbook of Flexible and Smart Sheet Forming Techniques

Industry 4.0 Approaches

Edited by

Ajay

Department of Mechanical Engineering, School of Engineering and Technology, JECRC University, Jaipur, Rajasthan, India

Parveen

Department of Mechanical Engineering, Rawal Institute of Engineering and Technology, Faridabad, Haryana, India

Hari Singh

Department of Mechanical Engineering, NIT Kurukshetra, Thanesar, Haryana, India

Vishal Gulati

Department of Mechanical Engineering, Guru Jambheshwar University of Science and Technology, Hisar, Haryana, India

Pravin Kumar Singh

Clarivate, India

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About the Editors

Dr. Ajay

Dr. Ajay is currently serving as an associate professor in Mechanical Engineering Department, School of Engineering and Technology, JECRC University, Jaipur, Rajasthan, India. He received his Ph.D. in the field of Advanced Manufacturing from Guru Jambheshwar University of Science and Technology, Hisar, India, after B.Tech. (Hons.) and M.Tech. (Distinction) from Maharshi Dayanand University, Rohtak, India. His areas of research include artificial intelligence, materials, incremental sheet forming, additive manufacturing, advanced manufacturing, Industry 4.0, waste management, and optimization techniques. He has over 60 publications in international journals of repute including SCOPUS, Web of Science and SCI indexed database, and refereed international conferences. He has also co‐authored a textbook: Incremental Sheet Forming Technologies: Principles, Merits, Limitations, and Applications, CRC Press, Taylor and Francis. He has recently edited a book entitled Advancements in Additive Manufacturing: Artificial Intelligence, Nature Inspired and Bio‐Manufacturing, Elsevier. He has organized various national and international events including an international conference on Mechatronics and Artificial Intelligence (ICMAI‐2021) as conference chair. He has more than 15 national and international patents to his credit. He has supervised more than eight M.Tech. and Ph.D. scholars and numerous undergraduate projects/thesis. He has a total of 13 years of experience in teaching and research. He is a guest editor and a review editor of many reputed journals including Frontiers in Sustainability. He has contributed to many international conferences/symposiums as a session chair, expert speaker, member of editorial board. He has won several proficiency awards during the course of his career, including merit awards, best teacher awards, and so on.

He has been adviser of Association of Engineers and Technocrats (AET) and has also authored many in‐house course notes, lab manuals, monographs, and invited chapters in books. He has organized a series of faculty development Programs, international conferences, workshops, and seminars for researchers, Ph.D., undergraduate, and postgraduate students. His area of research includes additive manufacturing, die‐less sheet forming, and intelligent manufacturing systems. He is associated with many research, academic, and professional societies in various capacities.

https://scholar.google.co.in/citations?user=TmZS4JIAAAAJ&hl=en

Publons Profile: https://publons.com/researcher/1596469/ajay‐kumar

Research Gate: https://www.researchgate.net/profile/Ajay_Kumar349

ResearcherID: D‐5813‐2019

http://www.researcherid.com/rid/D‐5813‐2019

ORCID ID: https://orcid.org/0000‐0001‐7306‐1902

Mr. Parveen

Mr. Parveen is currently serving as an assistant professor in Department of Mechanical Engineering, Rawal Institute of Engineering and Technology, Faridabad, Haryana, India. Currently, he is pursuing Ph.D. from National Institute of Technology, Kurukshetra, Haryana, India. He completed his B.Tech. (Hons.) from Kurukshetra University, Kurukshetra, India, and M.Tech. (Distinction) in Manufacturing and Automation from Maharshi Dayanand University, Rohtak, India. His areas of research include materials, die‐less forming, additive manufacturing, CAD/CAM, and optimization techniques. He has over 20 publications in international journals of repute including SCOPUS, Web of Science and SCI indexed database, and refereed international conferences. He has five national and international patents to his credit. He has supervised two M.Tech. scholars and numerous undergraduate projects/thesis. He has a total of 12 years of experience in teaching and research.

He has organized a series of faculty development programs, workshops, and seminars for researchers and undergraduate students. His area of research includes additive manufacturing, die‐less sheet forming, material characterization techniques, intelligent manufacturing systems, and optimization techniques. He is associated with many research, academic, and professional societies in various capacities.

https://scholar.google.com/citations?hl=en&authuser=1&user=ESQ‐RnYAAAAJ

ORCID ID: https://orcid.org/0000‐0002‐2922‐6228

Prof. Hari Singh

Prof. Hari Singh is currently professor in Mechanical Engineering Department at NIT Kurukshetra, India. He completed his bachelor’s degree in mechanical engineering with Honors in 1987, master’s degree in mechanical engineering in 1994, and Ph.D. in 2001 from Regional Engineering College, Kurukshetra (now, NIT Kurukshetra). He has 34 years of teaching and research experience in the present institute. He has published 150 research papers in various journals of repute and national/international conference proceedings. He has attended a number of conferences abroad in Brazil, Australia, Hong Kong, Singapore, France, Italy, and the United Kingdom. He has supervised 15 Ph.D. students and 8 are in progress. He has also supervised 42 M.Tech. students for their dissertations. He has three patents to his credit. His areas of interest include conventional and unconventional manufacturing processes, product and process improvement, single‐ and multi‐response optimization, design of experiments, Taguchi methods, response surface methodology, and so on. He has membership of various professional societies like Institution of Engineers (India), Indian Society of Theoretical and Applied Mechanics (ISTAM), Indian Society of Technical Education (ISTE), and International Association of Engineers (IAENG).

https://scholar.google.com/citations?user=dYv_vf0AAAAJ&hl=en

Prof. Vishal Gulati

Prof. Vishal Gulati is currently professor in Mechanical Engineering Department at Guru Jambheshwar University of Science and Technology, Hisar, India. He completed his bachelor’s degree in Mechanical Engineering in 1998, master’s degree in Mechanical Engineering in 2003 from Regional Engineering College, Kurukshetra (now, NIT Kurukshetra), and Ph.D. in 2009 from National Institute of Technology, Kurukshetra. He has 23 years of teaching and research experience. He has published 55 research papers in various journals of repute and national/international conference proceedings. He has organized a number of faculty development programs, workshops, and seminars. He has attended and presented 25 papers in different conferences. He has supervised 2 Ph.D. students and 3 are in progress. He has also supervised 36 M.Tech. students for their dissertations. His areas of interest include CAD/CAM, product design and development, incremental sheet forming, etc. He has membership of various professional societies like Institution of Engineers (India), Indian Society of Technical Education (ISTE).

https://www.researchgate.net/profile/Vishal‐Gulati‐2

Dr. Pravin Kumar Singh

Dr. Pravin Kumar Singh is currently working with Clarivate (American analytics company), as a senior IP analyst, since December 2022. His current role is to ensure the patentability of new inventions, research, claims, features, ideas, products, etc. and to develop the strategies to protect intellectual property across technologies.

Dr. Pravin has around 8 years of teaching experience in reputed technical universities. He was associated with AMITY University, Jharkhand, in between 2017 and 2022. He was HOD of Mechanical Engineering department. He also worked as an assistant professor in Lovely Professional University, Jalandhar, India, from 2011 to 2013.

Dr. Singh has completed his PhD degree from the National Institute of Technology, Jamshedpur, India. His research area was Advance welding technology. He has completed his Certificate course (+2), Diploma, BE, and MTech in mechanical engineering with specialization of Welding technology from Sant Longowal Institute of Engineering and Technology (CFTI), India.

Dr. Pravin Kr. Singh – Google Scholar

Pravin Kumar Singh (researchgate.net)

https://orcid.org/0000‐0002‐5995‐3223

List of Contributors

Nahid AkhtarDepartment of Mechanical Engineering, Laxmi Devi Institute of Engineering and Technology, Alwar, Rajasthan, India

Monisha AwasthiSchool of Computing Sciences (USCS), Uttaranchal University, Dehradun, Uttarakhand, India

Ravindra ChopraDepartment of Mechanical Engineering, Modern Institute of Technology and Research Centre, Alwar, Rajasthan, India

Tushar R. DandekarDepartment of Metallurgical and Materials Engineering, Visvesvaraya National Institute of Technology (VNIT), Nagpur, Maharashtra, IndiaandDepartment of Metallurgical Engineering and Materials Science, Indian Institute of Technology Bombay Powai, Mumbai, Maharashtra, India

Soumyajit DasDepartment of Industrial and Management Engineering (IME), Indian Institute of Technology, Kanpur, Uttar Pradesh, India

Swapnil DeokarMechanical Engineering, Smt. Kashibai Navale College of Engineering, Pune, India

Namrata DograDepartment of Orthodontics and Dentofacial Orthopedics, Faculty of Dental Sciences, SGT University, Gurugram, Haryana, India

Ankur GoelDepartment of Business Administration, MIT, MIET Group, Meerut, Uttar Pradesh, India

Edurne IriondoDepartment of Mechanical Engineering, University of the Basque Country, Bilbao, Spain

Archana JaglanDepartment of Orthodontics and Dentofacial Orthopedics, Faculty of Dental Sciences, SGT University, Gurugram, Haryana, India

Prashant K. JainMechanical Engineering, PDPM Indian Institute of Information Technology, Design and Manufacturing, Jabalpur, India

Rajesh K. KhatirkarDepartment of Metallurgical and Materials Engineering, Visvesvaraya National Institute of Technology (VNIT), Nagpur, Maharashtra, India

Ajay KumarDepartment of Mechanical Engineering, School of Engineering and Technology, JECRC University, Jaipur, Rajasthan, India

Mukesh KumarDepartment of Mechanical Engineering, Manipal University Jaipur, Jaipur, Rajasthan, India

Parveen KumarDepartment of Mechanical Engineering, Rawal Institute of Engineering and Technology, Faridabad, Haryana, India

Rupesh KumarMechanical Engineering Department, National Institute of Technology, Kurukshetra, Haryana, India

Sunil KumarDepartment of Computer Science and Engineering, Meerut Institute of Engineering and Technology, Meerut, Uttar Pradesh, India

Vikas KumarMechanical Engineering Department, National Institute of Technology, Kurukshetra, Haryana, India

Olasumbo Ayodeji MakindeDepartment of Quality and Operations Management, University of Johannesburg, Johannesburg, South Africa

Sushma MalikInstitute of Innovation in Technology & Management, Janakpuri, New Delhi, India

Khumbulani MpofuDepartment of Industrial Engineering, Tshwane University of Technology, Pretoria, South Africa

Mamatha NakkaDepartment of Chemistry, VNR Vignana Jyothi Institute of Engineering and Technology, Hyderabad, Telangana, India

Olayinka Mohammed OlabanjiDepartment of Industrial Engineering, Tshwane University of Technology, Pretoria, South Africa

Mikel OrtizTECNALIA, Basque Research and Technology Alliance (BRTA), Parque Científico y Tecnológico de Guipúzcoa, Donostia‐San Sebastián, Spain

Mariluz PenalvaTECNALIA, Basque Research and Technology Alliance (BRTA), Parque Científico y Tecnológico de Guipúzcoa, Donostia‐San Sebastián, Spain

Mildred PuertoTECNALIA, Basque Research and Technology Alliance (BRTA), Parque Científico y Tecnológico de Guipúzcoa, Donostia‐San Sebastián, Spain

Boitumelo Innocent RamatsetseDepartment of Mechanical and Mechatronics Engineering, Stellenbosch University, Stellenbosch, South Africa

Anamika RanaMaharaja Surajmal Institute, Janakpuri, New Delhi, India

M. Rami ReddyDepartment of Physics, Acharya Nagarjuna University, Nagarjuna Nagar, Andhra Pradesh, India

Antonio RubioTECNALIA, Basque Research and Technology Alliance (BRTA), Parque Científico y Tecnológico de Guipúzcoa, Donostia‐San Sebastián, Spain

K. S. RudramambaDepartment of Physics, VNR Vignana Jyothi Institute of Engineering and Technology, Hyderabad, Telangana, India

Dilip Kumar Jang Bahadur SainiDepartment of Computer Science and Engineering, Himalayan School of Science and Technology Swami Rama Himalayan University (SRHU), Dehradun, Uttarakhand, India

Dhirendra SiddharthDepartment of Computer Sciences and Engineering, Sreenidhi Institute of Science and Technology, Hyderabad, Telangana, India

Maite Ortiz de ZarateTECNALIA, Basque Research and Technology Alliance (BRTA), Parque Científico y Tecnológico de Guipúzcoa, Donostia‐San Sebastián, Spain

Preface

Flexible and smart sheet forming processes that do not require time consuming, set‐up operations and/or do not impose the use of expensive conventional equipment have become a rather promising research topic. They enable the economical production of prototypes and small batch production and allow for the adaptation and modification of the product geometry with little effort. Incremental Sheet Forming (ISF) is a novel sheet forming process that eliminates the use of expensive dies and reduces tooling costs for the manufacturing of complex sheet material parts, which makes it ideal for manufacturing prototypes and low‐volume production as compared to other traditional sheet material forming processes. ISF also finds suitability for producing sheet material components of old machinery, which are otherwise very difficult and non‐economical to produce due to the unavailability of forming dies. The ISF process is a die‐less process that uses a simple forming tool, which is made to move along a controlled tool‐path for forming the sheet locally layer by layer, into the desired shape. This technique is a major breakthrough in the sheet material forming processes without using a punch and die.

This book discusses recent developments in Incremental Sheet Forming from various mechanical, automobile, industrial, and aerospace engineering perspective and how this technology interacts with green manufacturing with incorporating Industry 4.0 approaches. It highlights the advancements involved in proper utilization of sheet forming techniques, including various optimizations like artificial intelligence, Internet of Things, machine learning techniques and simulation approaches. Written in a didactic style, it offers a guide and insights into Incremental Sheet Forming process. Each chapter provides in‐depth technical information on the Incremental Sheet Forming theory and its advancement. The book shows how Incremental Sheet Forming may help us solve human and environmental issues in the future and suggests where current research may lead. In addition, this book presents a collection of studies on state‐of‐art techniques developed specifically for Flexible and smart Sheet Forming with an emphasis on using various analytical strategies, computational and simulation approach, artificial intelligence approach to develop innovative sheet forming technique. The book offers an ideal reference guide for academic researchers and industrial engineers in the fields of Incremental Sheet Forming. It can also be used as a comprehensive reference source for university students in automobile, production, industrial and mechanical engineering, and in medical sector.

Since the information related to smart and flexible sheet forming is scattered into patents and research publications and not at one place in a systematic form, editors recognize their ethical responsibility to compile, share, and spread the knowledge accumulated and technology developed, with the students, researchers and industry people, to draw the benefits of this work in the form of a book and gain technical competence in the frontal area.

The book consists of thirteen chapters that describe “Flexible and Smart Sheet Forming Techniques: Industry 4.0 Perspectives” in different aspects. Chapter 1 “Incremental Sheet Forming – A State‐of‐Art Review” intends to give the overview of various incremental sheet forming methods, materials required for sheet forming and explain their formability limits. Chapter 2 “Classification of Incremental Sheet Forming” discusses various classification based on different forming methods, tools, paths, machines and hot‐forming. Chapter 3 “A Review on Effect of Computer‐Aided Machining Parameters in Incremental Sheet Forming” explains parameters response such as surface roughness, forming forces, dimensional accuracy, formability, thickness reduction, and energy consumption in ISF. Chapter 4 “Equipment and Operative for Industrializing the SPIF of Ti‐6Al‐4V” focuses on the Ti‐6Al‐4V alloy and a dedicated hot Single Point Incremental Forming (SPIF) system with its operative to ensure the optimal geometric accuracy of the final part. Chapter 5 “Texture Development During Incremental Sheet Forming (ISF): A State‐of‐the‐Art Review” discusses texture development, microstructure evolution, and deformation mechanism during ISF are reviewed systematically. Various characterization tools such as electron back‐scattered diffraction (EBSD), scanning electron microscope (SEM), X‐ray diffraction, and mechanical tests were used to carry out the studies on the effect of microstructure and texture development on improvement in formability. Chapter 6 “Analyses of Stress and Forces in Single‐Point Incremental Sheet Metal Forming” utilizes LS‐DYNA a holistic methodology for numerical simulation of ISF and the effects of the critical parameters like von mises stress and forces on geometry acting have been investigated. Chapter 7 “Finite Element Simulation Approach in Incremental Sheet Forming Process” explores the applications of finite element method analysis in incremental sheet forming processes. Chapter 8 “Detection of Defect in Sheet Metal Industry: An Implication of Fault Tree Analysis” aims to find the root cause of metal forming defects and solve them by adopting smart technologies in contrast to Industry 4.0. A fault‐tree analysis (FTA) diagram represents in such a way that the basic causes of sheet metal forming are underlined and also a reliability investigation is presented in graphical format. Chapter 9 “Integration of IoT, Fog, and Cloud‐Based Computing‐Oriented Communication Protocols in Smart Sheet Forming” gives a general overview of the many communication protocols utilized in smart sheet creation via integration of IoT, Cloud and Fog‐based computing (ITCFBC). Chapter 10 “Blockchain for the Internet of Things and Industry 4.0 Application” discusses how blockchain may support manufacturing applications for smart manufacturing. Chapter 11 “Experimental Study on the Fabrication of Plain Weave Copper Strips Mesh‐Embedded Hybrid Composite and Its Benefits Over Traditional Sheet Metal” deals with investigating the mechanical properties and physical properties of two types of composites, which are GFRP composites and hybrid composites. A GFRP composite was made using a composition of 20% e‐glass fiber as a reinforcement and epoxy resin LY556 as a matrix material. A plain weave copper strip mesh of a thickness of 35 gauge or 0.213 mm was added in between the layers of fiberglass in the GFRP composite. Both composites were fabricated by using the hand lay‐up moulding process and followed ASTM standards for testing. Chapter 12 “Application of Reconfigurable System Thinking in Reconfigurable Bending Machine and Assembly Systems” describe the evolution, factors of emergence, classification, types, characteristics, enabling tools and technologies, challenges, contribution and case studies of reconfigurable machines in non‐conventional machining areas for efficient production of components and parts used in manufacturing industries. Chapter 13 “Application of Incremental Sheet Forming (ISF) Toward Biomedical and Medical Implants” highlights the overview of ISF, materials used for the production of implants, the application of ISF in the production of biomedical and medical implants.

This book is intended for both the academia and the industry. The postgraduate students, PhD students and researchers in universities and institutions, who are involved in the areas of Smart and Flexible Sheet forming techniques utilizing Industry 4.0 approaches, will find this compilation useful.

The editors acknowledge the professional support received from WILEY and express their gratitude for this opportunity.

Reader’s observations, suggestions, and queries are welcome.

Editors

Ajay

Parveen

Hari Singh

Vishal Gulati

Pravin Kumar Singh

1Incremental Sheet Forming – A State‐of‐Art Review

K. S. Rudramamba1, M. Rami Reddy2, and Mamatha Nakka3

1 Department of Physics, VNR Vignana Jyothi Institute of Engineering and Technology, Hyderabad, Telangana, India

2 Department of Physics, Acharya Nagarjuna University, Nagarjuna Nagar, Andhra Pradesh, India

3 Department of Chemistry, VNR Vignana Jyothi Institute of Engineering and Technology, Hyderabad, Telangana, India

1.1 Introduction to Incremental Sheet Forming

In the present scenario, technology and automation have paved the path for innovation in various manufacturing sectors and professions. Automation of manufacturing process requires digital transformation to improve the value of a product or business model [1–4]. The improvement in the value of product or business model depends on flexibility and mass customization during manufacturing phase. Industry 4.0 intends to improve productivity and efficiency in manufacturing phase which lead to flexible manufacturing system (FMS). The economy has improved due to mass customization by FMS [4]. The incremental sheet forming (ISF) with Industry 4.0 technologies such as artificial intelligence (AI), internet of things (IoT), deep learning, and block chain technology is one of the FMSs to enhance production process [5, 6]. The supply chain efficiency in manufacturing phase has boosted up with the effective usage of resources and thereby increased the sustainability of the product [3]. The impact of ISF with Industry 4.0 on the sustainability of products is shown in Figure 1.1.

These days, customer needs and interests have been demanding tailored products from small batch production. ISF, which was developed in Japan (1994) to meet the needs in automotive field, is a prominent process to produce various parts of sheet metal. Later, many advances have taken place in this field to meet the wide variety of industrial needs in supply chain [7, 8]. The review on various sheet forming methods, materials and technologies used in initial stage of sheet metal production is essential [9, 10]. The basic concepts in ISF process along with formability was extensively reviewed by Jeswiet et al. [11]. To enhance the production size to large scale and to compete with strict industrial 4.0 standards, more emphasis on methods of ISF is required. Further, the materials with formability and applicability are to be reviewed systematically to identify the scope for advancement. For the systematic approach, this chapter gives overview of various forming methods, materials used, applicability, and future trends in ISF from literature.

Figure 1.1 Impact of incremental sheet forming with Industry 4.0 technologies.

1.2 Incremental Sheet Forming Process

The process of deforming a sheet of metal progressively by using a simple tool to get desired shape via localized deformation is called ISF. In this process, the metal sheet is clamped between two fixtures, and a simple deforming tool that can be controlled by a computer numerical control (CNC) controller machine is placed on the top surface of the sheet. External pressure or additional tools are not used for deformation. The tool path strategy for deformation is very important in conventional ISF. The classification of ISF based on strategic tool path techniques includes single‐stage and multi‐stage forming. The single‐stage forming of sheet depends on the sheet thickness “t” and wall angle “α” (see Figure 1.2). The sine law, which is shown in Eq. (1.1), holds good for single‐stage forming [10]. The final thickness “T ” of sheet after deformation is given as,

(1.1)

In single stage, the deforming tool moves initially along the sheet and further proceeds vertically to deform layers and produce final shape of the product (see Figure 1.3a).

Figure 1.2 Representation of wall angle “α”.

Adapted from [11].

Though single‐stage incremental forming depends on wall angle, it has been noticed that the fracture occurred even at an angle less than 90° [12]. Hence, the wall angle is to be tuned to avoid fracture. The vertical wall developed by the single‐stage incremental forming creates more uncertainty in the rate of production. The following changes can be implemented to increase the success rate of single‐stage forming:

Adjusting the initial thickness of the sheet based on wall angle.

Redistributing the formability of material.

Modifying the tool path.

Figure 1.3 (a) Single‐stage incremental sheet forming. (b) Multistage incremental sheet forming process.

But the above changes are limited to specific products only. The product cost and formability limits have become a hurdle in this process of forming sheet [13, 14]. The difficulty in forming vertical wall or 90° wall angles can be rectified by implementing multistage forming technique.

In multi‐stage incremental forming, three main stages are involved (see Figure 1.3b). They are initial (stage 1), intermediate (stage 2), and final (stage 3) stages.

In stage 1, the wall angle is limited to 50° to form the vertical wall of a product. Later in stage 2, the wall angle is increased by 10°–15° (say 65°) and in stage 3, the wall angle is further increased by 15° (say 80°) to get desired (cylindrical) shape of the product [14–17]. The sine law used in single‐stage forming is modified due to change in wall angle at stage 2. The modified sine law [9] is represented in Eq. (1.2).

(1.2)

In the above equation, t2 is the thickness of wall at stage 2 and t1 is the thickness of wall at stage 1. The wall angle is α1 at stage 1, and modified angle in stage 2 is α2.

The following methods are the four types of fundamental ISF methods:

Single‐point incremental sheet forming (SPISF)

Two‐point incremental sheet forming (TPISF)

Double‐sided incremental sheet forming (DSISF)

Hybrid incremental sheet forming (HISF)

1.2.1 Single‐Point Incremental Sheet Forming (SPISF)

The process of forming sheet metal products through a simple tool employed with CNC machine or robots in the absence of die is termed as SPISF. In this process, only single point of sheet is in contact with the tool. The tool path of the tool is predetermined to move horizontally along the plane of sheet. The upper surface of the sheet is in contact with the tool, whereas lower surface remains contact less. This process is also called as negative ISF as the deformation of fixed sheet by the tool is vertically inward [18] (see Figure 1.4).

The amount of deformation after each horizontal motion (contour) of tool is termed as step downsize, and it is important in evaluation of geometric accuracy and formability limits of sheet [19–21]. SPSIF is suitable for low‐volume production and produces concave and asymmetric shapes. The SPSIF is still an interesting method since a decade in manufacturing due to its key features like low forming force, high formability, and flexibility for change in design, with less time [21, 22]. Nevertheless, some setbacks have been identified by the researchers that confine this method to small‐scale rather than large‐scale production. The limiting factors that were observed were undesired bending and greater spring back [22, 23]. However, researchers tried to address and solve the setbacks in bending with the help of back clamping and geometric accuracy by modified tool path. But, the flexibility was seriously affected.

Figure 1.4 Single‐point incremental sheet forming (SPISF).

1.2.2 Two‐Point Incremental Sheet Forming (TPISF)

The process of forming sheet metal products using forming and supporting tools in the presence of partial or full die is termed as TPISF. In this process, the clamped metal sheet undergoes deformation by the forming tool with the help of the supporting tool, which is quite opposite to the deforming tool. The supporting tool, which is in contact with bottom surface of clamped sheet, provides support at the center of the sheet only. The deforming tool is in contact with top surface of metal sheet [24, 25] (see Figure 1.5). This method is called positive ISF because the deformation in metal sheet is directed outward. This process produces convex‐shaped products.

Figure 1.5 Two‐point incremental sheet forming (TPISF).

The TPISF is further divided into two methods. They are partial and full die TPIS. In partial die method, forming tool moves on the top surface of the metal and the bottom surface is supported by partial die to turn in to desired shape whereas in full die method, the bottom surface is supported by the full die to get desired shape (see Figure 1.6).

Figure 1.6 TPISF with partial die (left) and TPISF with full die (right).

Source: Adapted from [10].

Like SPISF, this method is also useful for low volume production [26]. Although TPISF has features similar to those of SPISF, disadvantages such as rise in cost and production time are encountered. Furthermore, the flexibility for the change in design is decreased due to the presence of partial and full dies as support. So, improved method of ISF is required to overcome the raised issues. The double‐sided incremental forming is the improved version which can provide the scope of cost‐effective production.

1.2.3 Double‐Sided Incremental Forming

The process of forming sheet metal products through two forming tools is termed as DSISF. The partial or full die in TPISF is replaced by another forming tool at the bottom of the clamped metal sheet. The forming tool acting on the top of the metal sheet is the main tool and at the bottom of the metal sheet is the counter tool. The counter tool follows the main tool to deform the sheet and hence called as slave tool [27] (see Figure 1.7).

The DSISF have the combined features of SPISF and TPISF. This method can produce concave, convex, and asymmetric shapes. It is also a die‐less process suitable for production at lower volumes. But the formability and accuracy are more when compared to earlier methods. It requires less forming force, and it is more flexible than TPISF.

The above‐discussed three (SPISF, TPISF, and DSISF) are the cold forming methods with some physical limitations during the deformation. They are mainly, geometric accuracy due to frequent change in movements of forming tool on surface, spring back, and material fracture at greater wall angles due to thinning of metal sheet. To overcome these issues, the method adopted is hybrid incremental forming.

1.2.4 Hybrid Incremental Forming

The hybrid method is referred to as the combination of stretching and ISF methods [28]. In this method, initially the metal was stretched to certain thickness and then clamped for ISF. In this method, the cycle time is reduced due to pre‐stretching of sheet. The thinning of sheet is more homogeneous than that of DSISF. In addition to that, the residual stress has been decreased due to tensile forces created during stretch forming, and the spring back is avoided [29]. When compared to earlier methods, the geometrical accuracy and formability have been enhanced. The use of specific dies in the sheet forming still increases the cost of production. Hence, this method should be improved to produce cost‐effective products.

Figure 1.7 DSISF method before (left) and after (right) simultaneous working of forming tool.

1.2.5 Thermal‐Assisted Incremental Forming (TAIF)

The strain hardening and residual stress propagation are the key factors for poor formability of product in cold incremental forming methods. The large amount of forming forces increases the capacity and power required for the machinery. Then the metal sheets in desired shape become expensive and affect the total production cycle. Some of the lightweight materials used in automotive, aerospace, and biomedical sectors require fine tuning of metal components. It is difficult to achieve geometrical accuracy for fine‐tuned molds and metal components by using cold incremental forming. The thermal‐assisted incremental forming is the best option to stretch the metal with less force, better formability and optimum strain hardening of the material [30]. The temperature greater than crystallization point of sheet material is used in thermal‐assisted incremental forming (TAIF) [31, 32]. The local heating and the global heating are the two kinds of heating strategies used in this method. The local heating strategy involves heating limited to a point on surface while the global heating strategy involves heating of the entire sheet. In this method, different types of sources are used to produce thermal energy (heat). The various sources used in thermal assistance method are summarized in Table 1.1.

The above insights into TAIF have shown its advantages over conventional incremental forming. Some issues have been raised during the implementation process. The nonuniform distribution of heat results in entropy of material, which in turn affects the mechanical properties of materials. The poor temperature control and motion of heating source are the main setbacks in the above process. The discussion has been done by researchers on employability of temperature sensor for automated control of temperature. But the moving source for thermal assistance became a major problem. From the modifications that were implemented in ISF to overcome the formability issues, it has been noticed that new knowledge on materials of sheet (specimen) can resolve the issues in a better way. Hence, a brief overview of materials used in incremental forming and various possibilities for technology assistance in improving the manufacturing process are discussed in the below section.

Table 1.1 Various heating strategies and sources in thermal‐assisted incremental forming methods.

Heating strategy and

Thermal assisting process

Ref.

Local heating using laser

The laser source is fixed at lower surface of the clamped sheet and made to move in the direction of forming tool

[33]

Local heating using laser

In this process, the laser source is placed at certain distance on same side of forming tool

[34]

Local heating‐hallogen lamp

Heat is not purely localized and extends to contact zone along with tool area.

[35]

Localheating‐electric source

It is an inexpensive process. The lower tool diameter and wall angle creates a spark to burn sheet metal due to localized accumulation of heat

[

36

,

37

]

Global heating – hot air blowers/hot air bands/hot oil

Un controlled heat in case of Hot air blowers. Non uniform distribution of heat in case of hot air bands and maximum heat for preparation of alloys is achieved in case of hot oil.

[

38

–

41

]

Global and local strategy heating band along with friction/pressure due to air or water assistance

With non‐uniform temperature, initially the whole sheet was heated and finally the localized area was heated again by high‐speed spindle motion or pressure created by air or water medium

[42]

1.3 Materials for Incremental Sheet Forming

Raw materials used in the ISF process play a major role in the manufacturing phase. In this new era of technologies advancement, AI can be used for selection of materials based on their properties and using correct processing technology for specific applications reducing their formability limits. This section emphasizes materials such as metals, polymers, composites, which are the most commonly used in ISF process.

Metals such as steel, aluminum, copper, titanium, magnesium, brass, and platinum alloy [9, 43] materials are widely used in as aircraft structures, ship panels, and automobile components, due to their superior mechanical properties such as ductility, fracture toughness, corrosion resistance, lightweight, and low cost [44, 45]. Rigorous changes in the ISF techniques such a tool path, tool radius, initial thickness, step size, and feed rate have improved the design of complex structures by reducing their formability limits.

These days, environmental protection concerns have driven the transportation industries including the battery electric vehicles and aircraft body panels to reduce products’ weight [46–49]. Aluminum and magnesium alloys benefit largely among the light‐weight materials due to their superior properties such as good corrosion resistance, high strength‐to‐weight ratio, and low density. The formability of magnesium is less or very low at room temperatures. A new process called rotational incremental sheet forming (RISF) has been proposed by attaching a high‐speed rotating tool that generates heat due to friction and attains the local temperature without using an external heating source, which improved the formability of magnesium [50]. Earlier, the usage of aluminum alloys in complex structural panels was restricted due to their low ductility at room temperature with the traditional manufacturing process. Presently, the rapid development in ISF technique has increased its potential applications in automotive industry. The main concerns of the incremental sheet process included thinning of the formed sheet, geometrical accuracy, and production efficiency, and these drawbacks were conquered by a hybrid process of stretch forming and single‐point ISF that reduced the time taken for processing and optimizing the geometrical accuracy and wall thickness [29]. It has been evident that the forming limits obtained by the forming tool along the grain boundaries have been limited with the appropriate use of lubricants having better finishing. In a recent study, the use of suitable minimum quantity lubrication (MQL) for effective single‐point incremental sheet process with constant SPIF parameters such as tool step down, feed rate have led to improved surface quality and dimensional accuracy by 14.60% [51].

In this new era of Industrial revolution 4.0, advancement in manufacturing technologies has enabled the use of lightweight and flexible polymeric materials in aerospace, automotive, and as biomedical implant using ISF technique [52, 53]. Most of the polymers such as PC, PVC, PA, and POM can be successfully processed using SPIF process at room temperature with good forming depths and drawing angles. Slight defects in the polymer formed sheet are explained by three failure models such as twist, circumferential crack, and oblique crack that affect the geometrical accuracy [54]. Twist failure in polymers is more severe compared to metals due to macromolecular structure and low mechanical properties of polymeric materials [55]. To avoid the failure mode of thermoplastic polymer, it was heated near the glass transition temperature, thereby enhancing the ductility of the sheet polymer and using alternate trajectory, twist phenomena in polymer is retained effectively [56]. It has been evident that PC sheets formability can be increased by 25% using small tool diameters with relatively low feed rate in SPIF. Digital image correlation system has been used to measure the principal strains at the cracked area [57].

Since last few decades, manufacturing methods related to metal‐based composites have attracted notable research attention with an idea of tailoring two materials having different properties, to get new material with unique properties. Single‐point incremental forming of bimetallic composite sheet has superior properties such as low density, good corrosion resistance, and high strength. Fiber reinforced composites (FRPs) have been widely used for automotive and aircraft structures. The concerns with these FRPs are poor impact resistance and fatigue failure of monolithic metallic structures [58, 59]. Fiber metal laminates are the hybrid materials that can overcome these fatigue deformations with rapid prototyping using ISF process that involves pumping hot air to heat Fiber metal laminate blank during the processing stage [60]. The formability, thickness variation surface roughness in different layer arrangements has the same process parameters. In CuAl composite, it has been noted that the deformation mode also depends upon the arrangement of layers of copper and aluminum through predictive modeling approaches [61].

Advanced manufacturing processes are oriented even to medical implants. The most commonly used biomedical implants in initial stage was stainless steel due to its good mechanical performance, cost, and reasonable biocompatibility. Only for temporary or short‐term use, stainless steel implants can be opted, as they can increase the infection risk with long‐term usage. High‐strength titanium alloys possessing good corrosion resistance are replaceable to stainless steel materials in biomedical application [62], but due to stress shielding these materials will increase the manufacturing complexities [63]