Skip to main content
SpringerLink
Log in

Integration of design rules and process modelling within SPIF technology-a review on the industrial dissemination of single point incremental forming

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

Abstract

Incremental sheet forming (ISF) processes like single-point incremental forming (SPIF) have been majorly studied since the beginning of the 2000s. Besides the applications in the prototyping field, ISF processes can also be used in the manufacture of unique parts and small batches. This capability led to new business possibilities, enabling the development of exclusive or custom products. Despite being a free-form manufacture process, ISF has some geometric limitations, mainly due to the forming mechanics and formability limit of the materials. Thus, it is important to establish well-defined guidelines to grant a feasible design. This paper presents a knowledge basis to design and manufacture ISF parts, mainly by SPIF. The possible part configurations and the design orientation are settled, allowing for a suitable part development. The hardware to perform incremental forming operations is outlined and the forming process is described, presenting alternative solutions. The process modelling is completed with a brief description of methods to improve part quality.

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. Adams D, Jeswiet J (2014) Design rules and applications of single-point incremental forming. Proc Inst Mech Eng B J Eng Manuf 229(5):253–262

    Google Scholar 

  2. Aerens R, Eyckens P, Bael AV, Duflou JR (2009) Force prediction for single point incremental forming deduced from experimental and fem observations. Int J Adv Manuf Technol 9(12): 969–982

    Google Scholar 

  3. Afonso D, Alves de Sousa R, Torcato R (2017) Incremental forming of tunnel type parts. In: 17th international conference on sheet metal, SHEMET17

  4. Afonso D, Alves de Sousa R, Torcato R, Sousa JP, Santos R, Valente R (2017) Case studies on industrial applicability of single point incremental forming. Ciência 2017—Encontro com a Ciência e Tecnologia em Portugal

  5. Allwood J, Houghton NE, Jackson KP (2005) The design of an incremental sheet forming machine. Adv Mater Res 6(8):471–478

    Article  Google Scholar 

  6. Alves de Sousa RJ, Ferreira JAF, Sá de Farias JB, Torráo JND, Afonso D, Martins MABE (2014) Spif-a: on the development of a new concept of incremental forming machine. Struct Eng Mech 59(5):645–660

    Article  Google Scholar 

  7. Ambrogio G, 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

    Article  Google Scholar 

  8. Amino M, Mizoguchi M, Terauchi Y, Maki T (2014) Current status of “dieless” amino’s incremental forming. Procedia Eng 81:54–62

    Article  Google Scholar 

  9. Aoyama S, Amino H, Lu Y, Matsubara S (2000) Apparatus for dieless forming plate materials. European Patent EP0970764

  10. Appermont R, Mieghem BV, Bael AV, Bens J, Ivens J, Vanhove H, Behera A, Duflou J (2012) Sheet-metal based molds for low-pressure processing of thermoplastics. In: Proceedings of the 5th bi-annual PMI conference, pp 383–388

  11. Azevedo NG, Farias JS, Bastos RP, Teixeira P, Davim JP, de Sousa RJA (2015) Lubrication aspects during single point incremental forming for steel and aluminum materials. Int J Precis Eng Manuf 16(3):589–595

    Article  Google Scholar 

  12. Bailly D, Bambach M, Hirt G, Pofahl T, Puppa GD, Trautz M (2015) Investigation on the producibility of freeform facade elements made of sheet metal as self-supporting structures by means of incremental sheet forming. In: The METEC and 2nd European steel technology and application days

  13. Bambach M, Araghi BT, Hirt G (2009) Strategies to improve the geometric accuracy in asymmetric single point incremental forming. Prod Eng Res Dev 3(2):145–156

    Article  Google Scholar 

  14. Baranovskaya Y (2016) A bridge too far, Complex Modelling, Centre for IT and Architecture, The Royal Danish Academy of Fine Arts- Schools of Architecture, Design and Conservation

  15. Bastos R, Alves de Sousa R, Ferreira JAF (2015) Enhancing time efficiency on single point incremental forming processes. Int J Mater Form 9(5):653–662

    Article  Google Scholar 

  16. Behera AK, Ou H (2016) Effect of stress relieving heat treatment on surface topography and dimensional accuracy of incrementally formed grade 1 titanium sheet parts. Int J Adv Manuf Technol 87(9–11):3233–3248

    Article  Google Scholar 

  17. Behera AK, Vanhove H, Lauwers B, Duflou J (2011) Accuracy improvement in single point incremental forming through systematic study of feature interactions. Key Eng Mater 473:881–888

    Article  Google Scholar 

  18. Behera AK, Verbert J, Lauwers B, Duflou J (2013) Tool path compensation strategies for single point incremental sheet forming using multivariate adaptive regression splines. Comput Aided Des 45(3):575–590

    Article  Google Scholar 

  19. Blaga A, Oleksik V (2013) A study on the influence of the forming strategy on the main strains, thickness reduction, and forces in a single point incremental forming process. Adv Mater Sci Eng 2013(382635):1–10

    Article  Google Scholar 

  20. Callegari M, Gabrielli A, Palpacelli MC, Principi M (2008) Incremental forming of sheet metal by means of parallel kinematics machines. ASME J Manuf Sci Eng 130(5):0545011–0545015

    Article  Google Scholar 

  21. Castelan J, Schaeffer L, Daleffe A, Fritzen D, Salvaro V, da Silva FP (2014) Manufacture of custom-made cranial implants from dicom® images using 3d printing, cad/cam technology and incremental sheet forming. Braz J Biomed Eng 30(3):265–273

    Google Scholar 

  22. Centeno G, Bagudanch I, Morales-Palma D, García-Romeu ML, Gonzalez-Perez-Somarriba B, Martinez-Donaire AJ, Gonzalez-Perez LM, Vallellano C (2017) Recent approaches for the manufacturing of polymeric cranial prostheses by incremental sheet forming. Procedia Eng 183:180–187

    Article  Google Scholar 

  23. Do VC, Nguyen DT, Cho JH, Kim YS (2016) Incremental forming of 3d structured aluminum sheet. Int J Precis Eng Manuf 17(2):217–223

    Article  Google Scholar 

  24. Duflou J, Lauwers B, Verbert J (2007) Study on the achievable accuracy in single point incremental forming. In: Advanced Methods in Material Forming. Springer, Berlin, Heidelberg

  25. Emmens W, van den Boogaard A (2009) An overview of stabilizing deformation mechanisms in incremental sheet forming. J Mater Process Technol 209:3688–3695

    Article  Google Scholar 

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

    Article  Google Scholar 

  27. European Commission (2016) EN Horizon 2020 Work Programme 2016–2017. European Commission

  28. Gardez SAR (2008) Economic analysis of low volume sheet metal products manufactured by single point incremental forming process. Master’s thesis, UET Lahore

  29. Gottmann 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

    Article  Google Scholar 

  30. Ham M, Jeswiet J (2008) Dimensional accuracy of single point incremental forming. Int J Mater Form Suppl 1:1171–1174

    Article  Google Scholar 

  31. Hussain G, Khan HR, Gao L, Hayat N (2013) Guidelines for tool-size selection for single-point incremental forming of an aerospace alloy. Mater Manuf Process 28(3):324–329

    Article  Google Scholar 

  32. Jeswiet J, Micarib F, Hirtc G, Bramleyc A, Dufloue J, Allwood J (2005) Asymmetric single point incremental forming of sheet metal. CIRP Ann Manuf Technol 54(2):88–114

    Article  Google Scholar 

  33. Jeswiet J, Adams D, Doolan M, McAnulty T, Gupta P (2015) Single point and asymmetric incremental forming. Adv Manuf 3(4):253–262

    Article  Google Scholar 

  34. Kalo A (2015) N-bowls. www.ammarkalo.com

  35. Kopac J, Kampus Z (2005) Incremental sheet metal forming on cnc milling machine-tool. J Mater Proc Tech 162–163: 622–628

    Article  Google Scholar 

  36. Lendel R, Milutinovic M, Ivanisevic A, Vilotic D, Movrin D, Skakun P (2014) Single point incremental forming of large-size components. J Technol Plast 39(1):59–66

    Google Scholar 

  37. Leszak E (1967) Apparatus and process for incremental dieless forming. E Patent US3342051A1

  38. Li Y, Daniel WJ, Liu Z, Lu H, Meehan PA (2015) Deformation mechanics and efficient force prediction in single point incremental forming. J Mater Process Technol 221:100–111

    Article  Google Scholar 

  39. Liu Z, Li Y, Meehan PA (2013) Vertical wall formation and material flow control for incremental sheet forming by revisiting multistage deformation path strategies. Mater Manuf Process 28:562–571

    Article  Google Scholar 

  40. Meier H, Dewald O, Zhang J (2005) A new robot-based sheet metal forming process. Adv Mater Res 6–8:465–470

    Article  Google Scholar 

  41. Micari F, Geiger M, Duflou J, Shirvani B, Clarke R, Lorenzo RD, Fratini L (2007) Incremental forming process for the accomplishment of automotive details. Key Eng Mater 344:559–566

    Article  Google Scholar 

  42. Paniti I (2014) New solutions in incremental sheet forming. Master’s thesis, Hungarian Academy of Sciences Institute for Computer Science and Control

  43. Penalva M (2014) Conformado incremental flexibilidad y bajo coste para la transformacin de chapa. interempresasnet

  44. Petek A, Kuzman K, Kopac J (2009) Deformations and forces analysis of single point incremental sheet metal forming. Arch Mater Sci Eng 35(2):107–116

    Google Scholar 

  45. Sá de Farias J, Ferreira J, Marabuto S, Campos AA, Martins M, de Sousa RA (2014) Smart manufacturing innovation and transformation: interconnection and intelligence. IGI Global, chap Towards Smart Manufacturing Techniques using Incremental Sheet Forming, pp 159–189

  46. Sá de Farias JB, Martins MABE, Afonso DG, Marabuto SR, Ferreira JAF, Alves de Sousa RJ (2013) Cad/cam strategies for a parallel kinematics spif machine. Key Eng Mater 554–557:2221–2229

    Article  Google Scholar 

  47. Silva MB, Skjødt M, Bay N, Martins PAF (2008) Theory of single point incremental forming. J Mater Process Technol 57(1):247–252

    Google Scholar 

  48. Skjødt M, Silva MB, Bay N, Martins PAF, Lenau T (2007) Single point incremental forming using a dummy sheet. In: Proceedings of the 2nd ICNFT - 2nd international conference on new forming technology, pp 267–276

  49. Skjødt M, Bay N, Endelt B, Ingarao G (2008) Multi stage strategies for single point incremental forming of a cup. In: Proceedings of the 11 conference on material forming ESAFORM

  50. Thyssen L, Seim P, Strökle D, Kuhlenkötte B (2016) On the increase of geometric accuracy with the help of stiffening elements for robot-based incremental sheet metal forming. In: 19th ESAFORM conference

  51. Vanhove H, Gu J, Sol H, Duflou J (2011) Process window extension for incremental forming through optimal work plane rotation. In: 10th international conference on technology of plasticity

  52. Vanhove H, Carette Y, Vancleef S, Duflou J (2017) Production of thin shell clavicle implants through single point incremental forming. Procedia Eng 183:174–179

    Article  Google Scholar 

  53. Zha G, Xu J, Shi X, Zhou X, Lu C (2015) Forming process of automotive body panel based on incremental forming technology. Metall Min Ind 2015(12):350–357

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. TEMA: Centre for Mechanical Technology and Automation, Department of Mechanical Engineering, University of Aveiro, Campus de Santiago, 3810-183, Aveiro, Portugal

    Daniel Afonso & Ricardo Alves de Sousa

  2. School of Design, Management and Production Technologies Northern Aveiro, University of Aveiro, Estrada do Cercal, 449, 3720-509, Santiago de Riba-Ul, Oliveira de Azeméis, Portugal

    Daniel Afonso & Ricardo Torcato

  3. Centre for Research in Ceramic and Composite Materials, CICECO, University of Aveiro, Campus de Santiago, 3810-183, Aveiro, Portugal

    Ricardo Torcato

Authors
  1. Daniel Afonso
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Ricardo Alves de Sousa
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Ricardo Torcato
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Daniel Afonso.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Afonso, D., Alves de Sousa, R. & Torcato, R. 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, 4387–4399 (2018). https://doi.org/10.1007/s00170-017-1130-3

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-017-1130-3

Keywords

Search

Navigation