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Exploring the deformation potential of composite materials processed by incremental sheet forming: a review

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Abstract

Over the past two decades, incremental sheet forming (ISF) has advanced the development of flexible sheet metal forming, especially for small-to-medium volume and customized production. To be suitable for various applications, researchers have explored the deformation potential of different materials, such as metals, polymers, composites, and so forth. For these materials, ISF-formed shapes and performances of the final components including formability, geometric accuracy, surface roughness, strength, and fatigue, etc. have been extensively assessed via analytical, numerical, and experimental approaches. This review article attempts to summarize the composite materials that are recognized and processed by ISF so far. Besides, deformation and failure mechanisms and constitutive equations used to describe their mechanical behaviors during ISF are discussed as well. The presented summary is aimed at aiding the ISF researchers in designing and manufacturing composite material components with desirable shapes and performances while providing a reference for future material characterizations related to sheet forming research.

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Data Availability

All data and materials are included in this article.

Code availability

No code is involved in this article.

Abbreviations

ISF:

Incremental sheet forming

SPIF:

Single-point incremental forming

TPIF:

Two-point incremental forming

DSIF:

Double-sided incremental forming

AISF:

Asymmetric incremental sheet forming

FSIF:

Friction stir incremental forming

ADSIF:

Accumulative double-sided incremental forming

Al:

Aluminum

Mg:

Magnesium

St:

Steel

Cu:

Copper or cuprum

FGM:

Functionally graded material

Ti:

Titanium

RVE:

Representative volume element

PP:

Polypropylene

FML:

Fiber metal laminate

ST:

Santoprene

PVC:

Polyvinyl chloride

SiCp:

Silicon carbide particles

PMMA:

Polymethyl methacrylate

f-MWCNTs:

Functionalized multi-wall carbon nanotubes

PLA:

Poly lactic acid

PA:

Polyamide

BFRP:

Basalt fiber–reinforced thermoplastic polymer

CFRP:

Carbon fiber–reinforced plastics

GFRP:

Glass fiber–reinforced plastics

FSTWB:

Friction stir tailor welded blank

FLD:

Forming limit diagrams

FFL:

Fracture forming line

FGBIT:

Fractal geometry–based incremental toolpath

SEM:

Scanning electron microscope

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Funding

The authors would like to thank the Start-up Funds from Wuhan University of Technology and the Fundamental Research Funds for the Central Universities (WUT: 2021-JD-B1-17) for undertaking this work.

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  1. School of Mechanical and Electronic Engineering, Wuhan University of Technology, Wuhan, 430070, China

    Zhaobing Liu, Kai Cheng & Kerui Peng

  2. Hubei Digital Manufacturing Key Laboratory, Wuhan University of Technology, Wuhan, 430070, China

    Zhaobing Liu

  3. Institute of Advanced Materials and Manufacturing Technology, Wuhan University of Technology, Wuhan, 430070, China

    Zhaobing Liu

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Zhaobing Liu: methodology, writing—review and editing, supervision, project administration. Kai Cheng: resources, writing—original draft, review, and editing. Kerui Peng: resources, writing—original draft.

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Liu, Z., Cheng, K. & Peng, K. Exploring the deformation potential of composite materials processed by incremental sheet forming: a review. Int J Adv Manuf Technol 118, 2099–2137 (2022). https://doi.org/10.1007/s00170-021-08081-4

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