Handbook of Flexible and Smart Sheet Forming Techniques

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