Handbook of Flexible and Smart Sheet Forming Techniques

Ajay, Ph.D. is Associate Professor in the Department of Mechanical Engineering, School of Engineering and Technology, JECRC University, Jaipur, Rajasthan, India. Parveen is an Assistant Professor in the Department of Mechanical Engineering, Rawal Institute of Engineering and Technology, Faridabad, Haryana, India. Hari Singh, Ph.D. is a Professor in the Mechanical Engineering Department at NIT Kurukshetra, Haryana, India. Vishal Gulati, Ph.D. is a Professor in the Mechanical Engineering Department at Guru Jambheshwar University of Science and Technology, Hisar, Haryana, India. Pravin Kumar Singh, Senior IP Analyst, Clarivate, India.

About the Editors xiii

List of Contributors xvii

Preface xxi

1 Incremental Sheet Forming – A State-of-Art Review 1
K. S. Rudramamba, M. Rami Reddy, and Mamatha Nakka

1.1 Introduction to Incremental Sheet Forming 1

1.2 Incremental Sheet Forming Process 2

1.2.1 Single-Point Incremental Sheet Forming (SPISF) 4

1.2.2 Two-Point Incremental Sheet Forming (TPISF) 4

1.2.3 Double-Sided Incremental Forming 5

1.2.4 Hybrid Incremental Forming 5

1.2.5 Thermal-Assisted Incremental Forming (TAIF) 6

1.3 Materials for Incremental Sheet Forming 7

1.4 Formability Limits with AI Implementation 9

1.5 Conclusions and Future Scope 9

References 10

2 Classification of Incremental Sheet Forming 15
Rupesh Kumar and Vikas Kumar

2.1 Introduction 15

2.1.1 History 16

2.2 Classification of ISF 17

2.2.1 Classification Based on Forming Methods of ISF 17

2.2.1.1 SPIF 18

2.2.1.2 TPIF 19

2.2.1.3 MPIF 20

2.2.1.4 Hybrid-ISF 20

2.2.2 Classification Based on Forming Tools of ISF 20

2.2.3 Classification Based on Forming Path of ISF 21

2.2.4 Classification Based on Forming Machine of ISF 22

2.2.5 Classification Based on Hot Forming of ISF 23

2.3 Conclusion 25

2.4 Future Work 25

References 25

3 A Review on Effect of Computer-Aided Machining Parameters in Incremental Sheet Forming 29
Rupesh Kumar, Vikas Kumar, and Ajay Kumar

3.1 Introduction 29

3.2 Process Parameters 29

3.2.1 Effects of Process Parameters on Surface Roughness 30

3.2.2 Effect of Process Parameters on Forming Force 31

3.2.3 Effect of Process Parameters on Formability 35

3.2.4 Effect of Process Parameters on Thickness Distribution 41

3.2.5 Effect of Process Parameters on Dimensional Accuracy 42

3.2.6 Effect of Process Parameters on the Processing Time 47

3.2.7 Effect of Process Parameters on Energy Consumption 48

3.3 Conclusion 49

3.4 Future Work 51

Funding Statement 52

Conflicts of Interest 52

Acknowledgment 52

References 53

4 Equipment and Operative for Industrializing the SPIF of Ti-6Al-4V 59
Mikel Ortiz, Mildred Puerto, Antonio Rubio, Maite Ortiz de Zarate, Edurne Iriondo, and Mariluz Penalva

4.1 Introduction 59

4.2 Materials and Methods 60

4.2.1 Original Equipment 60

4.2.2 Methodology 62

4.3 Results and Discussion 63

4.3.1 Hot SPIF System 63

4.3.1.1 Forming Temperatures Range 63

4.3.1.2 Concept 65

4.3.1.3 Heating Units and Control 66

4.3.1.4 Forming Tool 72

4.3.1.5 Costs Assessment 72

4.3.2 Hot SPIF of Ti-6Al-4V 75

4.3.2.1 Overview 75

4.3.2.2 Temperature Cycles 76

4.3.2.3 Practices for Higher Accuracy 79

4.3.2.4 Subsequent Operations 83

4.4 Conclusion 89

References 90

5 Texture Development During Incremental Sheet Forming (ISF): A State-of-the-Art Review 93
Tushar R. Dandekar and Rajesh K. Khatirkar

5.1 Introduction 93

5.2 Crystallographic Texture 94

5.2.1 Introduction to Crystallographic Texture 94

5.2.2 Texture Evolution During ISF 96

5.2.2.1 Texture Evolution During ISF of Aluminum Alloys 96

5.2.2.2 Texture Development in ISF of AA1050 Alloy in Three Stages of SPIF 97

5.3 Microstructure Evolution During ISF 102

5.3.1 Microstructures 102

5.3.2 Microstructure Evolution During ISF in Various Materials 103

5.3.2.1 AA5052 Aluminum Alloy 103

5.3.2.2 Dual Phase (DP590) Steel 105

5.4 Deformation Mechanism During ISF 107

5.4.1 Membrane Strain 107

5.4.2 Shear Deformation 108

5.4.3 Bending Under Tension (BUT) 110

5.5 Future Scope 111

5.6 Summary 111

Abbreviations 112

References 112

6 Analyses of Stress and Forces in Single-Point Incremental Sheet Metal Forming 117
Swapnil Deokar and Prashant K. Jain

6.1 Introduction 117

6.1.1 Classification of ISF Based on Forming Methods 118

6.2 Experimental Setup 119

6.2.1 Machining Parameters in ISF 119

6.2.2 Tool Path Strategies 120

6.3 FE Analysis of ISF 121

6.3.1 Analysis of Stress on Parts 121

6.3.2 Forces Behavior in ISF 122

6.3.3 Stress Effect on Thinning Part 122

6.3.4 Applications of ISF 124

6.3.5 Result and Discussion 124

6.3.5.1 Stress Behavior 124

6.3.5.2 Force Behavior 125

6.3.5.3 Thinning Characteristics 125

6.4 Conclusion 126

6.5 Future work 126

References 126

7 Finite Element Simulation Approach in Incremental Sheet Forming Process 129
Archana Jaglan, Namrata Dogra, Ajay Kumar, and Parveen Kumar

7.1 Introduction 129

7.2 Finite Element Simulation 130

7.2.1 Definition 130

7.2.2 History of Finite Element Method 131

7.2.3 Various Software Used for Finite Element Simulation in Incremental Sheet Forming Process 133

7.2.4 Categories and Types of Finite Element Method Simulation 134

7.2.5 Application of Finite Element Simulation in Incremental Sheet Forming Process 135

7.2.6 Advantages of Finite Element Simulation in Incremental Sheet Forming Process 137

7.3 Conclusion 138

References 138

8 Detection of Defect in Sheet Metal Industry: An Implication of Fault Tree Analysis 141
Soumyajit Das

8.1 Introduction 141

8.2 Methodology 142

8.2.1 Data Collection 142

8.2.2 Problem Description 142

8.2.3 FMEA Analysis 143

8.2.4 Fault Tree Analysis 143

8.2.5 Fishbone Diagram 145

8.3 Result and Analysis 146

8.4 Discussion 148

8.5 Conclusion 149

References 150

9 Integration of IoT, Fog- and Cloud-Based Computing-Oriented Communication Protocols in Smart Sheet Forming 151
Monisha Awasthi, Anamika Rana, Sushma Malik, and Ankur Goel

9.1 Introduction 151

9.2 Background 154

9.3 Communication Protocol Overview 156

9.3.1 HTTP: Hyper Text Transfer Protocol 157

9.3.2 CoAP: Constrained Application Protocols 157

9.3.3 MQTT: MQ Telemetry Transport 158

9.3.4 DDS: Data Distribution Services 159

9.3.5 AMQP: Advanced Message Queuing Protocol 160

9.3.6 XMPP: Extensible Messaging and Presence Protocol 160

9.4 Comparative Study of Communication Protocol for IoT Premise 161

9.5 IOT, FOG, and CLOUD (ITCFBC) Are Interrelated 162

9.6 Challenges and Related Issues 162

9.7 Conclusion and Future Scope 164

References 164

10 Blockchain for the Internet of Things and Industry 4.0 Application 167
Dhirendra Siddharth, Dilip Kumar Jang Bahadur Saini, and Sunil Kumar

10.1 Introduction 167

10.2 Blockchain’s Application in a Wide Range of Industries 168

10.2.1 Supply Chain 168

10.2.2 Financial Transactions 168

10.2.3 Encryption of Data 168

10.2.4 Product Information 168

10.2.5 Peer-to-Peer Trading 168

10.3 Blockchain Plays in the Future of Our Economy 169

10.3.1 The End of Corruption 169

10.3.2 Integrity 169

10.3.3 Contracts Without the Middle Person 170

10.3.4 No Financial Stand 170

10.3.5 Easier Management Without Analytics 170

10.4 Changes in Society Using the Internet of Things and Blockchain 170

10.4.1 Changes Through Blockchain 170

10.4.2 Changes Through the Internet of Things 171

10.5 Blockchain Transform Industries and the Economy 171

10.6 Blockchain Support Swinburne’s Industry 4.0 Strategy 172

10.7 Blockchain Technology’s Impact on the Digital Economy 173

10.7.1 Changes in the Architecture 173

10.7.2 Networking and Verification Expenses Are Reduced 173

10.7.3 Automation 174

10.8 Chains Are Being Revolutionized by Blockchain Technology 174

10.8.1 Manual Procedures Are Being Replaced 175

10.8.2 Increased Traceability 175

10.8.3 Reliability and Trustworthiness Are Being Improved 175

10.8.4 Processing Transactions in a Timely and Effective Manner 175

10.9 Businesses That Use Blockchain Technology 175

10.9.1 Blockchain Can Boost Supply Chain Value 175

10.10 Real-World Use Cases for dApps and Smart Contracts 176

10.10.1 Financial Use Cases for Smart Contracts 176

10.10.2 Gaming Using Blockchain Technology: NFTs and Smart Contracts 177

10.10.3 Blockchain and Smart Contracts in the Legal Industry 177

10.10.4 Real Estate and Blockchain 177

10.10.5 Creating DAOs with Smart Contracts for Corporate Structures 178

10.10.6 Smart Contracts in Emerging Technology Applications 178

10.10.7 Smart Contracts’ Potential Benefits in Other Industries 178

10.11 Blockchain Is About to Revolutionize the Courtroom 179

10.11.1 Enhanced Security Levels 179

10.11.2 Better Agreements 180

10.12 Conclusion 180

References 180

11 Experimental Study on the Fabrication of Plain Weave Copper Strips Mesh-Embedded Hybrid Composite and Its Benefits Over Traditional Sheet Metal 183
Ravindra Chopra, Mukesh Kumar, and Nahid Akhtar

11.1 Introduction 183

11.1.1 Composite Material: Overview 183

11.1.2 Classification of Composite Materials 183

11.1.3 Fiber-Reinforced Plastic (FRP) Composite Material 183

11.1.4 Advantages of Composites 185

11.1.5 Why Composites Are Replacing Traditional Sheet Metals 185

11.1.5.1 High Degree of Strength 185

11.1.5.2 Longer Life Span 186

11.1.5.3 Composites Allow New Design Possibilities 186

11.1.6 Applications of Hybrid Composites Over Sheet Metals 186

11.1.7 Failure Modes 186

11.1.8 Concerns About Disposal and Reuse 186

11.1.9 Problem Definition 187

11.1.10 Layout of the Project 187

11.1.11 Research Objectives 187

11.1.12 Research Application 187

11.2 Proposed Methodology 188

11.3 Experimental Procedure 188

11.3.1 Raw Materials 188

11.3.1.1 E-Glass Fiber (CSM) 190

11.3.1.2 Epoxy Resin (Araldite LY556) 191

11.3.1.3 Hardener (Aradur HY951) 191

11.3.1.4 Flat Copper Sheet 191

11.3.2 Mold Preparation 192

11.3.3 Releasing Agent 193

11.3.4 Plain Weave Copper Strips Mesh Preparation 193

11.3.5 Composite Preparation 193

11.3.6 De-Molding Process 196

11.3.7 Mechanical and Physical Studies of GFRP and Hybrid Composites 196

11.3.7.1 Tensile Strength Testing 197

11.3.7.2 Flexural Strength Testing 201

11.3.7.3 Izod Impact Strength Testing 202

11.3.7.4 Shore D Hardness Testing 202

11.3.7.5 Density Testing 203

11.4 Results and Discussions 205

11.4.1 Tensile Strength 205

11.4.2 Flexural Strength 206

11.4.3 Izod Impact Strength 207

11.4.4 Shore D Hardness 208

11.4.5 Density 209

11.5 Conclusions 210

11.6 Future Scope 211

References 211

12 Application of Reconfigurable System Thinking in Reconfigurable Bending Machine and Assembly Systems 213
Khumbulani Mpofu, Boitumelo Innocent Ramatsetse, Olasumbo Ayodeji Makinde, and Olayinka Mohammed Olabanji

12.1 Introduction: Background and Overview 213

12.1.1 Definition of Key Terms 213

12.2 Description of Machining, Bending, and Assembly Processes 214

12.3 Related Works on Manufacturing Systems 214

12.4 Conventional Sheet Metal Bending and Assembly System Technologies 215

12.4.1 Conventional Sheet Metal Bending Technologies 215

12.5 Trends and Evolution of Manufacturing System Paradigms 218

12.5.1 Classification of Press Brake Machines 218

12.5.2 Classification of Assembly System Technologies 221

12.5.2.1 Assembly Systems and Their Mode of Configuration 222

12.5.2.2 Assembly Systems Based on Their Mode of Operation 222

12.5.3 Application of RMS in Sheet Metal Bending Process 223

12.6 Case Studies for Application of RMS in Bending Operations 224

12.6.1 Description RBPM Machine 224

12.6.2 RMS Characteristics for RBPM Machine 226

12.7 Scalability Planning for RMS 227

12.7.1 Convertibility Assessment for Reconfigurable Manufacturing Systems 229

12.7.1.1 Incremental Conversion 230

12.7.1.2 Routing Connections 230

12.7.1.3 Routing Modules 230

12.8 Modularity Assessment for Reconfigurable Systems 236

12.9 Case Studies for Application of RMS in Assembly Operations 239

12.9.1 Description Reconfigurable Assembly Fixture 239

12.9.2 RMS Characteristics for RAF Machine 240

12.10 Conclusions 242

References 243

13 Application of Incremental Sheet Forming (ISF) Toward Biomedical and Medical Implants 247
Ajay Kumar, Parveen Kumar, Namrata Dogra, and Archana Jaglan

13.1 Introduction 247

13.1.1 Conventional Manufacturing Process 247

13.1.2 Incremental Sheet Forming 249

13.2 Classification of ISF 249

13.3 Process Parameters of ISF 250

13.3.1 Tool Path 251

13.3.2 Tool Size 251

13.3.3 Tool Rotation 251

13.3.4 Sheet Material 251

13.3.5 Forming Speed 251

13.3.6 Step Size 252

13.4 Materials for Fabrication of Implants 252

13.5 Methods of Implant Manufacturing 253

13.6 Applications of ISF Process 253

13.6.1 Cranial Implant 253

13.6.2 Facial Implant 255

13.6.3 Denture Base 257

13.6.4 Knee Prosthesis 257

13.7 Challenges of ISF Process 259

13.8 Future Scope of ISF 260

13.9 Conclusion 261

References 261

Index 265