Improvements On Single Point Incremental Forming Through Electrically Assisted Forming Contact Area Prediction And Tool Development

Single Point Incremental Forming (SPIF) is a die-less sheet metal forming method. Because SPIF does not use custom tooling, this process allows for parts to be made at low cost and short lead times. In this thesis electric current is applied through the tool to alter the formability of samples formed with SPIF. The research goal of this work is to determine if formability is effected by resistive heating alone or if there is some formability change due to the current interacting with the material. An apparatus that allows electrical current to be applied through the tool during forming is designed and implemented. A method is also developed to allow the contact area between the tool and sheet to be estimated, with particular focus on developing a method that allows for experimental measurement. The effect of applied current on formability is estimated by evaluating the maximum wall angle that can be formed in a single pass, using a variety of tool sizes and current settings. Using the contact area model to estimate current density, a signicant increase in formability is found at a current density range that agrees with previously published literature on electrically assisted forming of the same material. The results show that across multiple tool sizes, a significant increase in formability is observed when applying a current density (A/mm2) larger than the current threshold density published in the literature. A study is also performed to test the performance of a set of novel tool shapes. By using parabolic tools, it was found that formability can be improved while maintaining low surface roughness. Finally, a series of case studies are presented documenting the production several parts for a variety of design groups and researchers at Queen's University. These case studies provide examples for the uses of SPIF, as well as document the methods used to produce these parts in greater detail than is present in the literature.

This book presents selected proceedings of the 8th International and 29th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2021). It covers the recent developments in the areas of metal forming and machining techniques, incremental forming, microforming, nesting algorithms, process simulation, parameter analysis, tools and tooling, tool wear, condition monitoring, cyber physical systems, robotics, machine vision, intelligent manufacturing, enterprise manufacturing intelligence, etc. The contents of this book will be useful for students, researchers as well as industry professionals in the various fields of mechanical engineering.

This book discusses the general concept and applications of rapid tooling technologies and introduces the use of incremental forming for the development of rapid sheet tools. Methods and techniques for tool design and development are discussed, considering their manufacture using incremental forming and complementary processes. The mechanical and thermal performance of sheet metal tools is analyzed. Finally, possible applications are introduced, with the description of some case study examples.

Maximizing reader insights into the latest research findings and applications of Electrically-Assisted Forming (EAF) – whereby metals are formed under an electric current field – this book explains how such a process produces immediate improved formability of metals beyond the extent of thermal softening, and allows metals to be formed to greater elongation with lower mechanical energy as well as allowing for lightweight brittle metals such as magnesium and titanium to be formed without external heating or annealing, enabling the more effective use of these lightweight metals in design. Including case studies that illustrate and support the theoretical content and real-world applications of the techniques discussed, this book also serves to enrich readers understanding of the underlying theories that influence electro-plastic behaviour. The authors have extensive experience in studying Electrically-Assisted Forming and have written extensively with publications including experimental works, technical briefs, conference proceedings, journal articles, and analytical models.

Incremental Sheet Forming (ISF) exempts use of dies and reduces cost for manufacturing complex parts. Sheet metal forming is used for producing high-quality components in automotive, aerospace, and medical industries. This book covers the benefits of this new technology, including the process parameters along with various techniques. Each variant of this novel process is discussed along with the requirements of machinery and hardware. In addition, appropriate guidelines are also suggested regarding the relationship between process parameters and aspects of ISF process in order to ensure the applicability of the process on the industrial scale. This book will be a useful asset for researchers, engineers in manufacturing industries, and postgraduate level courses.

The three-volume set CCIS 923, CCIS 924, and CCIS 925 constitutes the thoroughly refereed proceedings of the First International Conference on Intelligent Manufacturing and Internet of Things, and of the 5th International Conference on Intelligent Computing for Sustainable Energy and Environment, ICSEE 2018, held in Chongqing, China, in September 2018.The 135 revised full papers presented were carefully reviewed and selected from over 385 submissions.The papers of this volume are organized in topical sections on: digital manufacturing; industrial product design; logistics, production and operation management; manufacturing material; manufacturing optimization; manufacturing process; mechanical transmission system; robotics.

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.

Micro Metal Forming, i. e. forming of parts and features with dimensions below 1 mm, is a young area of research in the wide field of metal forming technologies, expanding the limits for applying metal forming towards micro technology. The essential challenges arise from the reduced geometrical size and the increased lot size. In order to enable potential users to apply micro metal forming in production, information about the following topics are given: tribological behavior: friction between tool and work piece as well as tool wear mechanical behavior: strength and formability of the work piece material, durability of the work pieces size effects: basic description of effects occurring due to the fact, that the quantitative relation between different features changes with decreasing size process windows and limits for forming processes tool making methods numerical modeling of processes and process chains quality assurance and metrology All topics are discussed with respect to the questions relevant to micro metal forming. The description comprises information from actual research and the young history of this technology branch to be used by students, scientists and engineers in industry who already have a background in metal forming and like to expand their knowledge towards miniaturization. tribological behavior: friction between tool and work piece as well as tool wear mechanical behavior: strength and formability of the work piece material, durability of the work pieces size effects: basic description of effects occurring due to the fact, that the quantitative relation between different features changes with decreasing size process windows and limits for forming processes tool making methods numerical modeling of processes and process chains quality assurance and metrology All topics are discussed with respect to the questions relevant to micro metal forming. The description comprises information from actual research and the young history of this technology branch to be used by students, scientists and engineers in industry who already have a background in metal forming and like to expand their knowledge towards miniaturization.

Handbook of Modern Coating Technologies: Application and Development reviews recent applications and developments of modern coating technologies. The topics in this volume consist of role of antibacterial coatings in the development of biomaterials, insights of technologies for self-healing organic coatings, sensor applications, application of carbon nanotubes–based coating in the field of art conservation, oxide-based self-cleaning and corrosion-protective coatings, protective coatings for wood, applications of optical coatings on spectral selective structures, application of natural antimicrobial coating for controlling foodborne pathogens on meat and fresh produce, efficacy of antimicrobial coating in reducing pathogens on meat, composite membrane: fabrication, characterization, and applications, development of nanostructured HVOF coatings on high strength steel components for turbine blades, nanoscale multilayered composite coating, applications of sol–gel coatings, application of graphene in protective coating industry, application of coatings in outdoor high-voltage installations, defects and doping effects in thin films of transparent and conductive oxides, and functional coatings for lab-on-a-chip systems based on phospholipid polymers.

The Springer Reference Work Handbook of Manufacturing Engineering and Technology provides overviews and in-depth and authoritative analyses on the basic and cutting-edge manufacturing technologies and sciences across a broad spectrum of areas. These topics are commonly encountered in industries as well as in academia. Manufacturing engineering curricula across universities are now essential topics covered in major universities worldwide.