Abstract
Incremental sheet forming is an advanced manufacturing technique where a piece of sheet is shaped into a product by a series of small incremental localized deformations. It has revolutionized sheet shaping for small-batch production since its inception in the 1990s, providing an economical and effective alternative to sheet stamping and pressing, which are cumbersome and expensive. However, the materials with poor overall ductility at room temperatures are difficult to be formed by conventional incremental sheet forming. Therefore, several heat-assisted incremental sheet-forming methods have been developed by researchers trying to improve the formability of such materials and overcome the low geometrical accuracy as well. The aim of this paper is to provide a state-of-the-art review on the development of heat-assisted incremental sheet forming. It is hoped that the knowledge provided in this paper can facilitate readers working in this field to obtain a comprehensive view and take a step forward for future incremental forming of hard-to-deform materials at elevated temperatures.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Li Y, Chen X, Liu Z, Sun J, Li F, Li J, Zhao G (2017) A review on the recent development of incremental sheet-forming process. Int J Adv Manuf Technol 92(5):2439–2462
Duflou JR, Habraken A-M, Cao J, Malhotra R, Bambach M, Adams D, Vanhove H, Mohammadi A, Jeswiet J (2017) Single point incremental forming: state-of-the-art and prospects. Int J Mater Form
Behera AK, de Sousa RA, Ingarao G, Oleksik V (2017) Single point incremental forming: an assessment of the progress and technology trends from 2005 to 2015. J Manuf Process 27:37–62
McAnulty T, Jeswiet J, Doolan M (2017) Formability in single point incremental forming: a comparative analysis of the state of the art. CIRP J Manuf Sci Technol 16:43–54
Duflou JR, Callebaut B, Verbert J, De Baerdemaeker H (2007) Laser assisted incremental forming: formability and accuracy improvement. CIRP Ann 56(1):273–276
Duflou JR, Callebaut B, Verbert J, De Baerdemaeker H (2008) Improved SPIF performance through dynamic local heating. Int J Mach Tools Manuf 48(5):543–549
Callebaut, B., (2009) Sheet metal forming by laser forming and laser assisted incremental forming. Ph.D. thesis Katholieke Universiteit Leuven, Belgium
Göttmann A, Diettrich J, Bergweiler G, Bambach M, Hirt G, Loosen P, Poprawe R (2011) Laser-assisted asymmetric incremental sheet forming of titanium sheet metal parts. Prod Eng 5(3):263–271
Göttmann A, Bailly D, Bergweiler G, Bambach M, Stollenwerk J, Hirt G, Loosen P (2013) A novel approach for temperature control in ISF supported by laser and resistance heating. Int J Adv Manuf Technol 67(9):2195–2205
Mohammadi A, Vanhove H, Van Bael A, Duflou JR (2016) Towards accuracy improvement in single point incremental forming of shallow parts formed under laser assisted conditions. Int J Mater Form 9(3):339–351
Mohammadi A, Qin L, Vanhove H, Seefeldt M, Van Bael A, Duflou JR (2016) Single point incremental forming of an aged AL-cu-mg alloy: influence of pre-heat treatment and warm forming. J Mater Eng Perform 25(6):2478–2488
Mohammadi A, Vanhove H, Van Bael A, Seefeldt M, Duflou JR (2016) Effect of laser transformation hardening on the accuracy of SPIF formed parts. ASME J Manuf Sci Eng 139(1):011007–011007-12
Kim SW, Lee YS, Kang SH, Lee JH (2007) Incremental forming of Mg alloy sheet at elevated temperatures. J Mech Sci Technol 21(10):1518–1522
Ji YH, Park JJ (2008) Incremental forming of free surface with magnesium alloy AZ31 sheet at warm temperatures. Trans Nonferrous Metals Soc China 18:s165–s169
Ji YH, Park JJ (2008) Formability of magnesium AZ31 sheet in the incremental forming at warm temperature. J Mater Process Technol 201(1):354–358
Galdos L, Argandona ESD, Ulacia I, Arruebarrena G (2012) Warm incremental forming of magnesium alloys using hot fluid as heating media. Key Eng Mater 504-506:815–820
Durante M, Formisano A, Langella A, Capece Minutolo FM (2009) The influence of tool rotation on an incremental forming process. J Mater Process Technol 209(9):4621–4626
Park J, Kim J, Park N, Kim Y (2009) Study of forming limit for rotational incremental sheet forming of magnesium alloy sheet. Metall Mater Trans A 41(1):97
Nguyen D-T, Park J-G, Kim Y-S (2010) Combined kinematic/isotropic hardening behavior study for magnesium alloy sheets to predict ductile fracture of rotational incremental forming. Int J Mater Form 3(1):939–942
Nguyen D-T, Park J-G, Kim Y-S (2010) Ductile fracture prediction in rotational incremental forming for magnesium alloy sheets using combined kinematic/isotropic hardening model. Metall Mater Trans A 41(8):1983–1994
Otsu M, Matsuo H, Matsuda M, Takashima K (2010) Friction stir incremental forming of aluminum alloy sheets. Steel Res Int 81(9):942–945
Otsu M, Ichikawa T, Matsuda M, Takashima K (2011) Development of friction stir incremental forming. J Jpn Soc Technol Plast 52(603):490–494
Xu D, Wu W, Malhotra R, Chen J, Lu B, Cao J (2013) Mechanism investigation for the influence of tool rotation and laser surface texturing (LST) on formability in single point incremental forming. Int J Mach Tools Manuf 73:37–46
Xu D, Lu B, Cao T, Chen J, Long H, Cao J (2014) A comparative study on process potentials for frictional stir- and electric hot-assisted incremental sheet forming. Proc Eng 81:2324–2329
Ambrogio G, Gagliardi F, Bruschi S, Filice L (2013) On the high-speed single point incremental forming of titanium alloys. CIRP Ann 62(1):243–246
Ambrogio G, Gagliardi F (2015) Temperature variation during high speed incremental forming on different lightweight alloys. Int J Adv Manuf Technol 76(9):1819–1825
Ambrogio G, Ciancio C, Filice L, Gagliardi F (2016) Theoretical model for temperature prediction in incremental sheet forming—experimental validation. Int J Mech Sci 108-109:39–48
Buffa G, Campanella D, Fratini L (2013) On the improvement of material formability in SPIF operation through tool stirring action. Int J Adv Manuf Technol 66(9):1343–1351
Davarpanah MA, Mirkouei A, Yu X, Malhotra R, Pilla S (2015) Effects of incremental depth and tool rotation on failure modes and microstructural properties in single point incremental forming of polymers. J Mater Process Technol 222:287–300
Wang J, Li L, Jiang H (2016) Effects of forming parameters on temperature in frictional stir incremental sheet forming. J Mech Sci Technol 30(5):2163–2169
Baharudin, B. T. H. T.; Azpen, Q. M.; Sulaima, Shamsuddin; Mustapha, F., Experimental investigation of forming forces in frictional stir incremental forming of aluminum alloy AA6061-T6. Metals 2017, 7 (11), 1–15
Liu Z (2017) Friction stir incremental forming of AA7075-O sheets: investigation on process feasibility. Proc Eng 207:783–788
Uheida EH, Oosthuizen GA, Dimitrov DM, Bezuidenhout MB, Hugo PA (2018) Effects of the relative tool rotation direction on formability during the incremental forming of titanium sheets. Int J Adv Manuf Technol 96:3311–3319
Ambrogio G, Filice L, Manco GL (2008) Warm incremental forming of magnesium alloy AZ31. CIRP Ann 57(1):257–260
Ambrogio G, Filice L, Gagliardi F (2012) Formability of lightweight alloys by hot incremental sheet forming. Mater Des 34:501–508
Fan G, Gao L, Hussain G, Wu Z (2008) Electric hot incremental forming: a novel technique. Int J Mach Tools Manuf 48(15):1688–1692
Fan G, Sun F, Meng X, Gao L, Tong G (2010) Electric hot incremental forming of Ti-6Al-4V titanium sheet. Int J Adv Manuf Technol 49(9):941–947
Fan G, Gao L (2014) Mechanical property of Ti-6Al-4V sheet in one-sided electric hot incremental forming. Int J Adv Manuf Technol 72(5):989–994
Fan G, Gao L (2014) Numerical simulation and experimental investigation to improve the dimensional accuracy in electric hot incremental forming of Ti–6Al–4V titanium sheet. Int J Adv Manuf Technol 72(5):1133–1141
Le Van S, Nguyen Thanh N (2013) Hot incremental forming of magnesium and aluminum alloy sheets by using direct heating system. Proc Inst Mech Eng B J Eng Manuf 227(8):1099–1110
Shi X, Gao L, Khalatbari H, Xu Y, Wang H, Jin L (2013) Electric hot incremental forming of low carbon steel sheet: accuracy improvement. Int J Adv Manuf Technol 68(1):241–247
Adams D, Jeswiet J (2014) Single point incremental forming of 6061-T6 using electrically assisted forming methods. Proc Inst Mech Eng B J Eng Manuf 228(7):757–764
Bao W, Chu X, Lin S, Gao J (2015) Experimental investigation on formability and microstructure of AZ31B alloy in electropulse-assisted incremental forming. Mater Des 87:632–639
Honarpisheh M, Abdolhoseini MJ, Amini S (2016) Experimental and numerical investigation of the hot incremental forming of Ti-6Al-4V sheet using electrical current. Int J Adv Manuf Technol 83(9):2027–2037
Khazaali H, Fereshteh-Saniee F (2016) A comprehensive experimental investigation on the influences of the process variables on warm incremental forming of Ti-6Al-4V titanium alloy using a simple technique. Int J Adv Manuf Technol 87(9):2911–2923
Liu R, Lu B, Xu D, Chen J, Chen F, Ou H, Long H (2016) Development of novel tools for electricity-assisted incremental sheet forming of titanium alloy. Int J Adv Manuf Technol 85(5):1137–1144
Najafabady SA, Ghaei A (2016) An experimental study on dimensional accuracy, surface quality, and hardness of Ti-6Al-4 V titanium alloy sheet in hot incremental forming. Int J Adv Manuf Technol 87(9):3579–3588
Xu DK, Lu B, Cao TT, Zhang H, Chen J, Long H, Cao J (2016) Enhancement of process capabilities in electrically-assisted double sided incremental forming. Mater Des 92:268–280
Li Z, Lu S, Zhang T, Zhang C, Mao Z (2017) 1060 Al electric hot incremental sheet forming process: analysis of dimensional accuracy and temperature. Trans Indian Inst Metals
Li Z, Lu S, Zhang T, Zhang C, Mao Z (2018) Electric assistance hot incremental sheet forming: an integral heating design. Int J Adv Manuf Technol
Magnus CS (2017) Joule heating of the forming zone in incremental sheet metal forming: part 1. Int J Adv Manuf Technol 91(1):1309–1319
Magnus CS (2017) Joule heating of the forming zone in incremental sheet metal forming: part 2. Int J Adv Manuf Technol 89(1):295–309
Min J, Seim P, Störkle D, Thyssen L, Kuhlenkötter B (2017) Thermal modeling in electricity assisted incremental sheet forming. Int J Mater Form 10(5):729–739
Pacheco PAP, Silveira ME (2017) Numerical simulation of electric hot incremental sheet forming of 1050 aluminum with and without preheating. Int J Adv Manuf Technol
Meier H, Magnus C, Buff B, Zhu J (2013) Tool concepts and materials for incremental sheet metal forming with direct resistance heating. Key Eng Mater 549:61–67
Al-Obaidi A, Kräusel V, Landgrebe D (2016) Hot single-point incremental forming assisted by induction heating. Int J Adv Manuf Technol 82(5):1163–1171
Al-Obaidi A, Kräusel V, Landgrebe D (2017) Induction heating validation of dieless single-point incremental forming of AHSS. J Manuf Mater Process 1(1):1–10
Ambrogio G, Gagliardi F, Chamanfar A, Misiolek WZ, Filice L (2017) Induction heating and cryogenic cooling in single point incremental forming of Ti-6Al-4V: process setup and evolution of microstructure and mechanical properties. Int J Adv Manuf Technol 91(1):803–812
Palumbo G, Brandizzi M (2012) Experimental investigations on the single point incremental forming of a titanium alloy component combining static heating with high tool rotation speed. Mater Des 40:43–51
Zhang Q, Guo H, Xiao F, Gao L, Bondarev AB, Han W (2009) Influence of anisotropy of the magnesium alloy AZ31 sheets on warm negative incremental forming. J Mater Process Technol 209(15):5514–5520
Zhang Q, Xiao F, Guo H, Li C, Gao L, Guo X, Han W, Bondarev AB (2010) Warm negative incremental forming of magnesium alloy AZ31 sheet: new lubricating method. J Mater Process Technol 210(2):323–329
Ambrogio G, De Napoli L, Filice L, Gagliardi F, Muzzupappa M (2005) Application of incremental forming process for high customised medical product manufacturing. J Mater Process Technol 162-163:156–162
Duflou J.; Lauwers B.; Verbert J.; Gelaude F.; Tunckol Y.,(2005) Medical application of single point incremental forming: cranial plate manufacturing. In: Proceedings of the 2nd international conference on advanced research in virtual and rapid prototyping. 161–166
Bagudanch I, Lozano-Sánchez LM, Puigpinós L, Sabater M, Elizalde LE, Elías-Zúñiga A, Garcia-Romeu ML (2015) Manufacturing of polymeric biocompatible cranial geometry by single point incremental forming. Proc Eng 132:267–273
Lu B, Xu DK, Liu RZ, Ou H, Long H, Chen J (2015) Cranial reconstruction using double side incremental forming. Key Eng Mater 639:535–542
Behera AK, Lu B, Ou H (2016) Characterization of shape and dimensional accuracy of incrementally formed titanium sheet parts with intermediate curvatures between two feature types. Int J Adv Manuf Technol 83(5):1099–1111
Duflou JR, Behera AK, Vanhove H, Bertol LS (2013) Manufacture of accurate titanium Cranio-facial implants with high forming angle using single point incremental forming. Key Eng Mater 549:223–230
Araujo R, Teixeira P, Montanari L, Reis A, Silva MB, Martins PA (2014) Single point incremental forming of a facial implant. Prosthetics Orthot Int 38:369–378
Oleksik V.; Pascu A.; Deac C.; Fleaca R.; Roman M.; Bologa O.,(2010) The influence of geometrical parameters on the incremental forming process for knee implants analyzed by numerical simulation. NUMIFORM , 1208–1215
Fiorentino A.; Marenda G.P.; Marzi R.; Ceretti E.; Kemmoku D.T.; Silva J.V.L., (2011) Rapid prototyping techniques for individualized medical prosthesis manufacturing. In: Innovative developments in virtual and physical prototyping. CRC Press , 589–594
Fiorentino A, Marzi R, Ceretti E (2012) Preliminary results on Ti incremental sheet forming (ISF) of biomedical devices: biocompatibility, surface finishing and treatment. Int J Mechatronics Manuf Syst 5:36–45
Eksteen P.D.; Van der Merwe A.F.,(2012) Incremental sheet forming (ISF) in the manufacturing of titanium based plate implants in the bio-medical sector. In: Proceedings of the international conference on computers & industrial engineering (CIE 42) 569–575
Eksteen P.D.,(2013) [Thesis (MScEng)] Development of incrementally formed patient-specific titanium knee prosthesis. Stellenbosch University
Vanhove H, Carette Y, Vancleef S, Duflou JR (2017) Production of thin shell clavicle implants through single point incremental forming. Proc Eng 183:174–179
Bambach M, Araghi BT, Hirt G (2009) Strategies to improve the geometric accuracy in asymmetric single point incremental forming. Prod Eng 3:145–156
Li JC, Shen JJ, Wang B (2013) A multipass incremental sheet forming strategy of a car taillight bracket. Int J Adv Manuf Technol 69:2229–2236
Okada M, Kato T, Otsu M, Tanaka H, Miura T (2018) Development of optical-heating-assisted incremental forming method for carbon fiber reinforced thermoplastic sheet-Forming characteristics in simple spot-forming and two-dimensional sheet-fed forming. J Mater Process Technol 256(6):145–153
Funding
This research is supported by the Fundamental Research Funds for the Central Universities (WUT 2017IVA017 and 2017III047).
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Liu, Z. Heat-assisted incremental sheet forming: a state-of-the-art review. Int J Adv Manuf Technol 98, 2987–3003 (2018). https://doi.org/10.1007/s00170-018-2470-3
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-018-2470-3