Skip to main content
SpringerLink
Log in

Contribution to a biomedical component production using incremental sheet forming

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Incremental sheet forming (ISF) is a relatively recent technology that allows producing highly custom-made components at a reasonable manufacturing cost. Single-point incremental sheet forming (SPIF) is one of the easiest ISF processes. In this sense, recent published results have revealed an increasing interest in shaping components for biomedical uses. This paper focuses on the establishment of a platform dedicated to produce biomedical complex geometry component. The main issue to be carried out is to improve the quality and the precision of manufactured products. The study shows the feasibility of socket fittings, applied to the femoral amputees, aimed at slowing wear between friction surfaces. The thinning has been analyzed as a formability indicator; also, the surface roughness has been addressed. The experimental results show a significant effect of the spindle speed in the ISF process of the increment on the surface roughness swept by the tool/sheet contact and the forming force. The analysis carried out on the deformed sheet shows a slight offset between the programmed surface, representing the real model, and the deformed surface obtained at the end of the process.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Jeswiest J, Micari J, Hirt G, Bramley A, Duflou J, Allwood J (2005) Asymmetric single point incremental forming of sheet metal. CIRP Ann Manuf Technol 54(2):88–114. https://doi.org/10.1016/S0007-8506(07)60021-3

    Article  Google Scholar 

  2. Ambrogio G, Denapoli L, Filice L, Gagliardi F, Muzzupappa M (2005) Application of incremental forming process for high customized medical product manufacturing. J Mater Process Technol 162–163:156–162

    Article  Google Scholar 

  3. Duflou J, Lauwers B, Verbert J, Gelaude F, Tunckol Y (2005) Medical application of single point incremental forming: cranial plate manufacturing. In: Bártolo (ed) Virtual modelling and rapid manufacturing–advanced research in virtual and rapid prototyping. Taylor & Francis Group, London, ISBN 0 415 39062 1, pp 161–166

    Google Scholar 

  4. 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. AIP Conf Proc 1252(1):1208–1215

    Article  Google Scholar 

  5. Lu B, Ou H, Shi SQ, Long H, Chen J (2016) Titanium based cranial reconstruction using incremental sheet forming. Int J Mater Form 9(3):361–370. https://doi.org/10.1007/s12289-014-1205-8

    Article  Google Scholar 

  6. Tanaka S, Nakamura T, Hayakawa K, Nakamura H, Motomura K (2007) Residual stress in sheet metal parts made by incremental forming process. AIP Conf Proc 908(1). https://doi.org/10.1063/1.2740904

  7. Bhoyar PK, Borade AB (2015) The use of single point incremental forming for customized implants of unicondylar knee arthroplasty: a review. Res Biomed Eng 31(4):352–357

    Article  Google Scholar 

  8. Eksteen PD, Van der Merwe AF (2012) Incremental sheet forming (ISF) in the manufacturing of titanium based plate implants in the bio-medical sector. CIE42 Proceedings, 16–18 July 2012, Cape Town, South Africa, pp 1311–1317

  9. Vanhove H, Carette Y, Vancleef S, Duflou JR (2017) Production of thin shell clavicle implants through single point incremental forming. Procedia Eng 183:174–179. https://doi.org/10.1016/j.proeng.2017.04.058

    Article  Google Scholar 

  10. Mitsuishi M, Cao J, Bártolo P, Friedrich D, Shih AJ, Rajurkar K, Sugita N, Harada K (2013) Biomanufacturing. CIRP Ann Manuf Technol 62(2):585–606. https://doi.org/10.1016/j.cirp.2013.05.001

    Article  Google Scholar 

  11. Franzen V, Kwiatkowski L, Martins P, Tekkaya A (2009) Single point incremental forming of PVC. J Mater Proc Technol 209(1):462–469. https://doi.org/10.1016/j.jmatprotec.2008.02.013

    Article  Google Scholar 

  12. Boulila A, Jendoubi K, Chabrand P, Zghal A, Khadhraoui M (2008) Contribution à l’étude de l’usure des prothèses totales de hanche–Approche expérimentale sur simulateur. Mech Ind 9(4):323–333

    Google Scholar 

  13. 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 Mechatron Manuf Syst 5(1):36–45

    Google Scholar 

  14. Bhoyar PK, Borade AB, Bhalerao SV (2016) Application of single point incremental forming for biomedical implants: a review. Int J Eng Appl Technol 8(2):1–5 ISSN: 2321-8134 SKNSITS RTME

    Google Scholar 

  15. Saidi B, Giraud-Moreau L, Cherouat A, Nasri R (2017) Experimental and numerical study on optimization of the single point incremental forming of AINSI 304L stainless steel sheet. J Phys Conf Ser 896:012039. https://doi.org/10.1088/1742-6596/896/1/012039

    Article  Google Scholar 

  16. Hirt G, Ames J, Bambach M, Kopp R (2004) Forming strategies and process modelling for CNC incremental sheet forming. CIRP Ann 53(1):203–206. https://doi.org/10.1016/S0007-8506(07)60679-9

    Article  Google Scholar 

  17. Fiorentino A, Attanasio A, Marzi R, Giardini C (2011) On forces, formability and geometrical error in metal incremental sheet forming. Int J Mater Prod Technol 40(3–4):277–295. https://doi.org/10.1504/IJMPT.2011.039936

    Article  Google Scholar 

  18. Khan MS, Coenen F, Dixon C, El-Salhi S, Penalva M, Rivero A (2015) An intelligent process model: predicting springback in single point incremental forming. Int J Adv Manuf Technol 76(9–12):2071–2082. https://doi.org/10.1007/s00170-014-6431-1

    Article  Google Scholar 

  19. Martins P, Bay N, Skjoedt M, Silva M (2008) Theory of single point incremental forming. CIRP Ann Manuf Technol 57(1):247–252. https://doi.org/10.1016/j.cirp.2008.03.047

    Article  Google Scholar 

  20. Hill R (1952) On discontinuous plastic states, with special reference to localized necking in thin sheets. J Mech Phys Solids 1(1):19–30. https://doi.org/10.1016/0022-5096(52)90003-3

    Article  MathSciNet  Google Scholar 

  21. Marciniak Z, Kuczyński K (1967) Limit strains in the processes of stretch-forming sheet metal. Int J Mech Sci 9(9):609–620. https://doi.org/10.1016/0020-7403(67)90066-5

    Article  MATH  Google Scholar 

  22. Stoughton TB (2000) A general forming limit criterion for sheet metal forming. Int J Mech Sci 42(1):1–27. https://doi.org/10.1016/S0020-7403(98)00113-1

    Article  MATH  Google Scholar 

  23. Petek A, Kuzman K, Suhač B (2009) Autonomous on-line system for fracture identification at incremental sheet forming. CIRP Ann Manuf Technol 58(1):283–286. https://doi.org/10.1016/j.cirp.2009.03.092

    Article  Google Scholar 

  24. Fiorentino A (2013) Force-based failure criterion in incremental sheet forming. Int J Adv Manuf Technol 68(1):557–563. https://doi.org/10.1007/s00170-013-4777-4

    Article  MathSciNet  Google Scholar 

  25. Duflou J, Verbert J, Belkassem B, Gub J, Sol H, Henrard C, Habraken A (2008) Process window enhancement for single point incremental forming through multi-step toolpaths. CIRP Ann Manuf Technol 57(1):253–256. https://doi.org/10.1016/j.cirp.2008.03.030

    Article  Google Scholar 

  26. Skjoedt M, Bay N, Endelt B, Ingarao G (2008) Multi stage strategies for single point incremental forming of a cup. Int J Mater Form 1(Suppl. 1):1199–1202. https://doi.org/10.1007/s12289-008-0156-3

    Article  Google Scholar 

  27. Fu Z, Mo J, Han F, Gong P (2013) Tool path correction algorithm for single-point incremental forming of sheet metal. Int J Adv Manuf Technol 64(9):1239–1248. https://doi.org/10.1007/s00170-012-4082-7

    Article  Google Scholar 

  28. Jeswiet J, Adams D, Doolan M, McAnulty T, Gupta P (2015) Single point and asymmetric incremental forming. Adv Manuf 3(4):253–262. https://doi.org/10.1007/s40436-015-0126-1

    Article  Google Scholar 

  29. Behera A, Lauwers B, Duflou J (2015) Tool path generation for single point incremental forming using intelligent sequencing and multi-step mesh morphing techniques. Int J Mater Form 8(4):517–532. https://doi.org/10.1007/s12289-014-1174-y

    Article  Google Scholar 

  30. Junchao L, Junjian S, Bin W (2013) A multipass incremental sheet forming strategy of a car taillight bracket. Int J Adv Manuf Technol 69(9):2229–2236. https://doi.org/10.1007/s00170-013-5179-3

    Article  Google Scholar 

  31. Radu C, Cristea I, Herghelegiu E, Tabacu S (2013) Improving the accuracy of parts manufactured by single point incremental forming. Appl Mech Mater 332:443–448. https://doi.org/10.4028/www.scientific.net/AMM.332.443

    Article  Google Scholar 

  32. Bahloul R, Arfa H, BelHajSalah H (2013) Application of response surface analysis and genetic algorithm for the optimization of single point incremental forming process. Key Eng Mater Key 554–557:1265–1272

    Article  Google Scholar 

  33. Lenka PK, Choudhury AR (2011) Analysis of trans tibial prosthetic socket materials using finite element method. J Biomed Sci Eng 4(12):762–768. https://doi.org/10.4236/jbise.2011.412094

    Article  Google Scholar 

  34. Papacharalampopoulos A, Polyzos D (2011) Wave propagation of Rayleigh waves in bones: a gradient viscoelastic approach. 10th International Workshop on Biomedical Engineering, Kos, 978-1-4577-0554-0/11/$26.00 ©2011 IEEE

  35. Sanders JE, Daly CH (1993) Normal and shear stresses on a residual limb in a prosthetic socket during ambulation-comparison of finite element results with experimental measurements. J Rehabil Res Dev 30(21):191–204

    Google Scholar 

  36. Michael S, Christof H, Frank S, Simone O, Bastian W (2013) Loads on the prosthesis-socket interface of above-knee amputees during normal gait-validation of a multi-body simulation. J Biomech 46(5):1201–1206

    Google Scholar 

  37. David AB, Toshiki K, Teri GC, Adam KA, Ming Z (2012) Perception of socket alignment perturbations in amputees with transtibial prostheses. J Rehabil Res Dev 49(6):843–854

    Article  Google Scholar 

  38. Boone DA, Kobayashi T, Chou TG, Arabian AK, Coleman KL, Orendurff MS, Zhang M (2013) Influence of malalignment on socket reaction moments during gait in amputees with transtibial prostheses. Gait Posture 37(4):620–626. https://doi.org/10.1016/j.gaitpost.2012.10.002

    Article  Google Scholar 

  39. Salonitis K, Stavropoulos P, Paralikas G, Chryssolouris G (2007) Modeling of cold roll forming process: a preliminary theoretical investigation. IFAC workshop on manufacturing modelling, management and control MIM’07, November 14–16 Budapest, Hungary

  40. Colombo G, Facoetti G, Rizz C (2013) A digital patient for computer-aided prosthesis design. Interface Focus 3(2):1–13. https://doi.org/10.1098/rsfs.2012.0082

    Article  Google Scholar 

  41. Li M, Zhang L-C, Mo J-H, Lu Y (2012) Tool-path generation for sheet metal incremental forming based on STL model with defects. Int J Adv Manuf Technol 63(5):535–547. https://doi.org/10.1007/s00170-012-3935-4

    Article  Google Scholar 

  42. Durante M, Formisano A, Langella A (2010) Comparison between analytical and experimental roughness values of components created by incremental forming. J Mater Process Technol 210(14):1934–1941. https://doi.org/10.1016/j.jmatprotec.2010.07.006

    Article  Google Scholar 

  43. Liu Z, Liu S, Li Y, Meehan PA (2014) Modeling and optimization of surface roughness in incremental sheet forming using a multi-objective function. Mater Manuf Process 29(7):808–818. https://doi.org/10.1080/10426914.2013.864405

    Article  Google Scholar 

  44. Hussain G, Gao L, NU D (2007) An experimental study on some formability evaluation methods in negative incremental forming. J Mater Process Technol 186(1–3):45–53. https://doi.org/10.1016/j.jmatprotec.2006.12.005

    Article  Google Scholar 

  45. Gatea S, Ou H, McCartney G (2016) Review on the influence of process parameters in incremental sheet forming. Int J Adv Manuf Technol 87(1–4):479–499. https://doi.org/10.1007/s00170-016-8426-6

    Article  Google Scholar 

  46. Thakur R, Kumar N (2015) Optimization of surface roughness and improving profile accuracy in SPIF (single point incremental forming) process. Int J Curr Eng Technol 5(3):2048–2052

    Google Scholar 

  47. Mulay A, Ben BS, Ismail S, Kocanda A (2017) Experimental investigation and modeling of single point incremental forming for AA5052-H32 aluminum alloy. Arab J Sci Eng 42(11):4929–4940. https://doi.org/10.1007/s13369-017-2746-1

    Article  Google Scholar 

  48. Kurra S, Rahman NH, Regalla SP, Gupta AK (2015) Modeling and optimization of surface roughness in single point incremental forming process. J Mater Res Technol 4(3):304–313. https://doi.org/10.1016/j.jmrt.2015.01.003

    Article  Google Scholar 

  49. Bahloul R, Arfa H, BelHadjSalah H (2014) A study on optimal design of process parameters in single point incremental forming of sheet metal by combining box–Behnken design of experiments, response surface methods and genetic algorithms. Int J Adv Manuf Technol 74(1–4):163–185. https://doi.org/10.1007/s00170-014-5975-4

    Article  Google Scholar 

  50. Aerens R, Eyckens P, Bael AV, Duflou JR (2010) Force prediction for single point incremental forming deduced from experimental and FEM observations. Int J Adv Manuf Technol 46(9–12):969–982. https://doi.org/10.1007/s00170-009-2160-2

    Article  Google Scholar 

  51. Dakhli M, Boulila A, Tourki Z (2017) Effect of generatrix profile on single-point incremental forming parameters. Int J Adv Manuf Technol 93(5–8):2505–2516. https://doi.org/10.1007/s00170-017-0598-1

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. National Institute of Applied Sciences and Technology, University of Carthage, Centre Urbain Nord, B.P 676, 1080, Tunis Cedex, Tunisia

    Atef Boulila

  2. National Engineering School of Bizerte, University of Carthage, Campus Universitaire Menzel Abderrahman, B.P 66, 7035, Bizerte, Tunisia

    Mahfoudh Ayadi

  3. Higher Institute of Technological Studies of Jendouba, Campus Universitaire, 8189, Jendouba Nord, Tunisia

    Sofiene Marzouki & Slim Bouzidi

Authors
  1. Atef Boulila
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Mahfoudh Ayadi
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Sofiene Marzouki
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Slim Bouzidi
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Atef Boulila.

Ethics declarations

Conflict of interest

The authors declare that they have no conflict of interest.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Boulila, A., Ayadi, M., Marzouki, S. et al. Contribution to a biomedical component production using incremental sheet forming. Int J Adv Manuf Technol 95, 2821–2833 (2018). https://doi.org/10.1007/s00170-017-1397-4

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-017-1397-4

Keywords

Search

Navigation