Skip to main content
SpringerLink
Log in

Investigation of forming parameters influence on pillow defect in a new vacuum-assisted incremental sheet forming process

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

A Correction to this article was published on 18 September 2023

This article has been updated

Abstract

The geometrical accuracy of incrementally formed products is the key focus in the incremental sheet forming (ISF) process. Pillow defect hinders the material’s formability, which limits geometrical accuracy. Therefore, considering the pillow defect as the major objective, the present study is aimed to evaluate the benefits of adding vacuum to the conventional ISF process for limiting the pillow effect. This work also studies the impact of forming parameters like tool diameter and vertical step increments on pillowing. Using the digital image correlation (DIC) technique, the material characteristics of AA5052 Al alloy were determined from a room-temperature tensile test. The vacuum-assisted ISF (VISF) experiments were then conducted, and the shape error was computed using the 3D scan data to check the part’s geometrical accuracy. The test results revealed that the forming tool diameter is the most important parameter, followed by the vertical step increment, affecting pillowing; with a small forming tool diameter, vacuum presence greatly reduced material pillowing. Besides, the vacuum uniformly deforms materials and controls shear deformation by balancing local element strain accumulation; however, when the tool diameter increased, the produced parts had no shear deformation. The numerical results showed that pillow formation largely relied on stress values from the forming tool motion and transverse directions and that the pillow height was lowered when the stress values were decreased in magnitude; however, there was no change in direction with a vacuum. In conclusion, the meaningful outcomes from the VISF process confirm the benefits of using vacuum to control pillowing.

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

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig.9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20

Similar content being viewed by others

Change history

Abbreviations

CNC:

Computer numerical control

ISF:

Incremental sheet forming

SPIF:

Single-point incremental forming

VISF:

Vacuum-assisted incremental sheet forming

HSS:

High-speed steel

FE:

Finite element

SS:

Stress (\(\sigma\))–strain (\(\varepsilon\))

DOE:

Design of experiments

CCD:

Central composite design

SEM:

Scanning electron microscope

ANN:

Artificial neural network

BP:

Back-propagation

ML:

Machine learning

RSM:

Response surface methodology

ANOVA:

Statistical analysis of variance

DMISF:

Double-sided incremental sheet forming

FS:

Friction stir-assisted

DIC:

Digital image correlation

FESEM:

Field emission scanning electron microscopy

EDS:

Energy-dispersive X-ray spectroscopy

References 

  1. Afonso D, Alves de Sousa R, Torcato R (2017) Integration of design rules and process modelling within SPIF technology-a review on the industrial dissemination of single point incremental forming. Int J Adv Manuf Technol 94(9–12):4387–4399

    Article  Google Scholar 

  2. Liu F, Li Y, Ghafoor S, Cheng Z, Li F, Li J (2021) Sustainability assessment of incremental sheet forming: a review. Int J Adv Manuf Technol 119(3–4):1385–1405

    Google Scholar 

  3. Murugesan M, Jung DW (2021) Formability and failure evaluation of AA3003-h18 sheets in single-point incremental forming process through the design of experiments. Materials 14(4):808

    Article  Google Scholar 

  4. Murugesan M, Yu J-H, Jung K-S, Cho S-M, Bhandari KS, Lee C-W (2022) Optimization of forming parameters in incremental sheet forming of AA3003-h18 sheets using taguchi method. Materials 15(4):1458

    Article  Google Scholar 

  5. Zheng K, Politis DJ, Wang L, Lin J (2018) A review on forming techniques for manufacturing lightweight complex—shaped aluminium panel components. Int J Lightweight Mater Manuf 1(2):55–80

    Google Scholar 

  6. Murugesan M, Sajjad M, Jung DW (2021) Experimental and numerical investigation of AA5052-h32 al alloy with u-profile in cold roll forming. Materials 14(2):470

    Article  Google Scholar 

  7. Trzepieciski T, Oleksik V, Pepelnjak T, Najm SM, Paniti I, Maji K (2021) Emerging trends in single point incremental sheet forming of lightweight metals. Metals 11(8):1188

    Article  Google Scholar 

  8. Haibo Lu, Liu H, Wang C (2019) Review on strategies for geometric accuracy improvement in incremental sheet forming. Int J Adv Manuf Technol 102(9–12):3381–3417

    Google Scholar 

  9. 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. IntJ Mater Form 11(6):743–773

    Article  Google Scholar 

  10. Cheng Z, Li Y, Changxu Xu, Liu Y, Ghafoor S, Li F (2020) Incremental sheet forming towards biomedical implants: a review. J Market Res 9(4):7225–7251

    Google Scholar 

  11. Dos Santos De Lucca G, Ferreira CA, Daleffe A, Fritzen D, Castelan J, Santos R, Schaeffer L (2021) Investigation of photofunctionalization applied to cranial implants produced by incremental sheet forming (ISF). J Mater Res Technol 15:2633–2645

    Article  Google Scholar 

  12. Emmens WC, Sebastiani G, van den Boogaard AH (2010) The technology of incremental sheet forming—a brief review of the history. J Mater Process Technol 210(8):981–997

    Article  Google Scholar 

  13. Gatea S, Hengan Ou, McCartney G (2016) Review on the influence of process parameters in incremental sheet forming. Int J Adv Manuf Technol 87(1–4):479–499

    Article  Google Scholar 

  14. 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

    Article  Google Scholar 

  15. Essa K, Hartley P (2010) An assessment of various process strategies for improving precision in single point incremental forming. IntJ Mater Form 4(4):401–412

    Article  Google Scholar 

  16. Li W, Attallah MM, Essa K (2022) Heat-assisted incremental sheet forming for high-strength materials — a review. Int J Adv Manuf Technol 124(7–8):2011–2036

    Google Scholar 

  17. Li W, Li S, Li X, Dongsheng Xu, Shao Y, Attallah MM, Essa K (2022) Crystal plasticity model of induction heating-assisted incremental sheet forming with recrystallisation simulation in cellular automata. Int J Adv Manuf Technol 123(3–4):903–925

    Article  Google Scholar 

  18. Yan Z, Hassanin H, El-Sayed MA, Eldessouky HM, Djuansjah JRP, Alsaleh NA, Essa K, Ahmadein M (2021) Multistage tool path optimisation of single-point incremental forming process. Materials 14(22):6794

    Article  Google Scholar 

  19. Li Y, Lu H, Daniel WJT, Meehan PA (2015) Investigation and optimization of deformation energy and geometric accuracy in the incremental sheet forming process using response surface methodology. Int J Adv Manuf Technol 79(9–12):2041–2055

    Article  Google Scholar 

  20. Dakhli M, Boulila A, Manach P-Y, Tourki Z (2019) Optimization of processing parameters and surface roughness of metallic sheets plastically deformed by incremental forming process. Int J Adv Manuf Technol 102(1–4):977–990

    Article  Google Scholar 

  21. Riaz AA, Hussain G, Ullah N, Wei H, Alkahtani M, Naeem Khan M (2021) An investigation on the effects of tool rotational speed and material temper on post-ISF tensile properties of al2219 alloy. J Mater Res Technol 10:853–867

    Article  Google Scholar 

  22. Chang Z, Huang W, Chen J (2020) A new tool path with point contact and its effect on incremental sheet forming process. Int J Adv Manuf Technol 110(5–6):1515–1525

    Article  Google Scholar 

  23. Liu Z, Li Y, Meehan PA (2014) Tool path strategies and deformation analysis in multi-pass incremental sheet forming process. Int J Adv Manuf Technol 75(1–4):395–409

    Article  Google Scholar 

  24. Ren H, Xie J, Liao S, Leem D, Ehmann K, Cao J (2019) In-situ springback compensation in incremental sheet forming. CIRP Ann 68(1):317–320

    Article  Google Scholar 

  25. Li J, Geng P, Shen J (2013) Numerical simulation and experimental investigation of multistage incremental sheet forming. Int J Adv Manuf Technol 68(9–12):2637–2644

    Article  Google Scholar 

  26. Duflou JR, Vanhove H, Verbert J, Gu J, Vasilakos I, Eyckens P (2010) Twist revisited: twist phenomena in single point incremental forming. CIRP Ann 59(1):307–310

    Article  Google Scholar 

  27. Wei H, Zhou L, Heidarshenas B, Ashraf IK, Han C (2019) Investigation on the influence of springback on precision of symmetric-cone-like parts in sheet metal incremental forming process. Int J Lightweight Mater Manuf 2(2):140–145

    Google Scholar 

  28. Li W, Attallah MM, Essa K (2022) Experimental and numerical investigations on the process quality and microstructure during induction heating assisted incremental forming of ti-6al-4v sheet. J Mater Process Technol 299:117323

    Article  Google Scholar 

  29. Li W, Essa K, Li S (2022) A novel tool to enhance the lubricant efficiency on induction heat-assisted incremental sheet forming of ti-6al-4 v sheets. Int J Adv Manuf Technol 120(11–12):8239–8257

    Article  Google Scholar 

  30. Li Y, Cheng Z, Chen X, Long Y, Li X, Li F, Li J, Twiefel J (2019) Constitutive modeling and deformation analysis for the ultrasonic-assisted incremental forming process. Int J Adv Manuf Technol 104(5–8):2287–2299

    Article  Google Scholar 

  31. Gao L, Zhao Y, Yu Z, Yan H (2020) Formability analysis of electrically assisted double-side multi-point incremental sheet forming. Int J Adv Manuf Technol 108(11–12):3405–3417

    Article  Google Scholar 

  32. Mohanraj R, Elangovan S (2020) Thermal modeling and experimental investigation on the influences of the process parameters on warm incremental sheet metal forming of titanium grade 2 using electric heating technique. Int J Adv Manuf Technol 110(1–2):255–274

    Article  Google Scholar 

  33. Bouhamed A, Jrad H, Said LB, Wali M, Dammak F (2018) A non-associated anisotropic plasticity model with mixed isotropic–kinematic hardening for finite element simulation of incremental sheet metal forming process. Int J Adv Manuf Technol 100(1–4):929–940

    Article  Google Scholar 

  34. Campanella D, Buffa G, Valvo EL, Fratini L (2021) A numerical approach for the modelling of forming limits in hot incremental forming of AZ31 magnesium alloy. Int J Adv Manuf Technol 114(11–12):3229–3239

    Article  Google Scholar 

  35. Ambrogio G, Cozza V, Filice L, Micari F (2007) An analytical model for improving precision in single point incremental forming. J Mater Process Technol 191(1–3):92–95

    Article  Google Scholar 

  36. Jackson K, Allwood J (2009) The mechanics of incremental sheet forming. J Mater Process Technol 209(3):1158–1174

    Article  Google Scholar 

  37. Wei H, Hussain G, Shi X, Isidore BBL, Alkahtani M, Abidi MH (2020) Formability of materials with small tools in incremental forming. Chin J Mech Eng 33(1)

  38. Nasulea D, Oancea G (2021) Achieving accuracy improvements for single-point incremental forming process using a circumferential hammering tool. Metals 11(3):482

    Article  Google Scholar 

  39. Al-Ghamdi KA, Hussain G (2014) The pillowing tendency of materials in single-point incremental forming: experimental and finite element analyses. Proc Inst Mech Eng, Part B: J Eng Manuf 229(5):744–753

    Article  Google Scholar 

  40. LemopisiIdore BB, Hussain G, PourhassanShamchi S, Khan WA (2016) Prediction and control of pillow defect in single point incremental forming using numerical simulations. J Mech Sci Technol 30(5):2151–2161

    Article  Google Scholar 

  41. Mohammed Najm S, Paniti I (2022) Study on effecting parameters of flat and hemispherical end tools in SPIF of aluminium foils. Tech Gazette 27(6)

  42. Prior AM (1994) Applications of implicit and explicit finite element techniques to metal forming. J Mater Process Technol 45(1–4):649–656

    Article  Google Scholar 

  43. Tamer ME, Music O, Ozdemir I, Baranoglu B, Sakin A, Durgun I (2013) Simulation for incremental sheet forming process: a comparison of implicit and explicit finite element analysis with experimental data. 7th international conference and exhibition on design and production of machines and dies/molds,Turkey

  44. Xiao X, Kim J-J, Seok-Hwan Oh, Kim Y-S (2021) Study on the incremental sheet forming of CFRP sheet. Compos A Appl Sci Manuf 141:106209

    Article  Google Scholar 

  45. Garca-Collado A, Medina-Sanchez G, Kumar Gupta M, Dorado-Vicente R (2020) Application of the finite element method to the incremental forming of polymer sheets: the thermomechanical coupled model and experimental validations. Polymers 12(8):1715

    Article  Google Scholar 

  46. Jung DW (1998) Study of dynamic explicit analysis in sheet metal forming processes using faster punch velocity and mass scaling scheme. J Mater Eng Perform 7(4):479–490

    Article  Google Scholar 

  47. Kim H, Park T, Esmaeilpour R, Pourboghrat F (2018) Numerical study of incremental sheet forming processes. J Phys: Conf Ser 1063:012017

    Google Scholar 

  48. Ziran X, Gao L, Hussain G, Cui Z (2009) The performance of flat end and hemispherical end tools in single-point incremental forming. Int J Adv Manuf Technol 46(9–12):1113–1118

    Article  Google Scholar 

Download references

Acknowledgements

We thank the Seoul National University of Science and Technology for supporting this research work financially.

Funding

This study was financially supported by the Seoul National University of Science and Technology.

Author information

Authors and Affiliations

  1. Department of Mechanical System Design Engineering, Seoul National University of Science and Technology, Seoul, 01811, South Korea

    Mohanraj Murugesan, Wanjin Chung & Chang-Whan Lee

  2. Molding and Metal Forming R&D Department, Korea Institute of Industrial Technology (KITECH), Incheon, 21999, South Korea

    Hyung-Won Youn

  3. Department of Mechanical Information Engineering, Seoul National University of Science and Technology, Seoul, 01811, South Korea

    Hyung-Won Youn, Jae-Hyeong Yu, Wanjin Chung & Chang-Whan Lee

Authors
  1. Mohanraj Murugesan
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Hyung-Won Youn
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Jae-Hyeong Yu
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Wanjin Chung
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Chang-Whan Lee
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Mohanraj Murugesan: conceptualization, data curation, investigation, validation, software, writing—original draft, writing—review and editing; Hyung-Won Youn: methodology, experiments, software; Jae-Hyeong Yu: methodology, experiments; Wanjin Chung and Chang-Whan Lee: supervision. All authors have read and agreed to the published version of the manuscript.

Corresponding author

Correspondence to Chang-Whan Lee.

Ethics declarations

Competing interests

The authors declare no competing interests.

Additional information

Publisher's note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

The original online version of this article was revised: Affiliations has been modified.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Murugesan, M., Youn, HW., Yu, JH. et al. Investigation of forming parameters influence on pillow defect in a new vacuum-assisted incremental sheet forming process. Int J Adv Manuf Technol 127, 5531–5551 (2023). https://doi.org/10.1007/s00170-023-11854-8

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-023-11854-8

Keywords

Search

Navigation