Recent Approaches for the Manufacturing of Polymeric Cranial Prostheses by Incremental Sheet Forming

This paper presents recent research experiences developed with the aim of manufacturing cranial prostheses in polymeric sheet using Incremental Sheet Forming (ISF) technologies. With this purpose, different approaches have been carried out in Single-Point Incremental Forming (SPIF) and Two-Point Incremental Forming (TPIF) in order to produce customized cranial implants using different polymeric materials. In this context, this research work provides a methodology to design and manufacture polymer customized cranial prostheses using the ISF technologies starting from a patient’s computerized tomography (CT). The results demonstrate the potential of manufacturing polymeric cranial prostheses by ISF in terms of the high formability achievable and show the appropriate geometrical accuracy at affordable manufacturing costs provided by these processes.Ministerio de Economía y Competitividad DPI2015-64047-

Numerical explicit analysis of hole flanging by single-stage incremental forming

The use of Single-Point Incremental Forming (SPIF) technology in hole flanging operations using multi-stages strategies have been widely studied in the last few years. However, these strategies are very time-consuming, limiting its industrial application.In a very recent work of the authors, the capability of SPIF process to successfully perform hole-flanges using a single-stage strategy has been experimentally investigated. The aim of the present work is to develop a numerical model of this process to beable to predict the sheet failure as a function of the size of the pre-cut hole. The numerical results are compared and discussed in the light of experimental tests over AA7075-O metal sheets with 1.6mm thickness.Ministerio de Economía y Competitividad DPI2015-64047-

An Attached Payload Operations Center (APOC) at the Goddard Space Flight Center (GSFC), volume 2

An overview of the APOC is given. For Spacelab payloads channel 2 and 3 data are input via a Statistical Multiplexer (SM) to the various SIPS functions. These include recording of the data on High Density Recorders (HDR), DQM and demultiplexing of the composite data stream by the High Rate Demultiplexer (HRDM). This system performs the inverse functions of the onboard Spacelab High Rate Multiplexer (HRM) enabling access to the data streams as multiplexed onboard the Spacelab. The contents and characteristics of channels one, two and three data as downlinked by the Tracking and Data Relay Satellite System (TDRSS) ku-band are given

Preliminary investigation on homogenization of the thickness distribution in hole-flanging by SPIF

A drawback of the hole-flanging process by single-stage SPIF is the non-uniform thickness obtained along the flange. Multi-stage strategies have been used to improve it, however they increase notably the manufacturing time. This work presents a preliminary study of the tool paths for a hole-flanging process by SPIF in two stages. An intermediate geometry of the piece is proposed from the analysis of the thickness distribution observed in previous single-stage process. A simple optimization procedure is used to automate the intermediate part design, the NC code generation for the tool path and the validation of the optimal forming strategy by means of FEA

The estimation of mixed demand systems

Horticulture;Consumer Choice

Simplified numerical approach for incremental sheet metal forming process

The current work presents a finite element approach for numerical simulation of the incremental sheet metal forming (ISF) process, called here ‘‘ISF-SAM’’ (for ISF-Simplified Analysis Modelling). The main goal of the study is to develop a simplified FE model sufficiently accurate to simulate the ISF process and quite efficient in terms of CPU time. Some assumptions have been adopted regarding the constitutive strains/stresses equations and the tool/sheet contact conditions. A simplified contact procedure was proposed to predict nodes in contact with the tool and to estimate their imposed displacements. A Discrete Kirchhoff Triangle shell element called DKT12, taking into account membrane and bending effects, has been used to mesh the sheet. An elasto-plastic constitutive model with isotropic hardening behaviour and a static scheme have been adopted to solve the nonlinear equilibrium equations. Satisfactory results have been obtained on two applications and a good correlation has been shown compared to experimental and numerical results, and at the same time a reduction of CPU time more than 60% has been observed. The bending phenomenon studied through the second application and the obtained results show the reliability of the DKT12 element

Efficient implicit simulation for incremental forming

Single Point Incremental Forming (SPIF) is a displacement controlled process performed on a CNC machine. A clamped blank is deformed by the movement of a small sized tool that follows a prescribed tool path. An extensive overview of the process has been given in [1]. The tool size plays a crucial role in the SPIF process. The small radius of the forming tool concentrates the strain at the zone of deformation in the sheet under the forming tool. The tool has to travel a lengthy forming path all over the blank to introduce the deformation. Numerically, this requires performing thousands of load increments on a relatively fine FE model resulting in enormous computing time. A typical computing time for implicit simulation of a small academic test is measured in by days. The focus of this paper is to efficiently use the implicit time integration method in order to reduce the required computing time for incremental forming implicit simulation drastically

Modelling of ductile fracture in single point incremental forming using a modified GTN model

Understanding the deformation and failure mechanisms in single point incremental forming (SPIF) is of great importance for achieving improved formability. Furthermore, there will be added benefits for more in depth evaluation of the effect of localised deformation to the fracture mechanism in SPIF. Although extensive research has been carried out in recent years, questions still remain on the shear and particularly its effect to the formability in SPIF processes. In this work, a modified Gurson–Tvergaard-Needleman (GTN) damage model was developed with the consideration of shear to predict ductile fracture in the SPIF process due to void nucleation and coalescence with results compared with original GTN model in SPIF. A combined approach of experimental testing and SPIF processing was used to validate finite element results of the shear modified Gurson–Tvergaard-Needleman damage model. The results showed that the shear modified GTN model improved the modelling accuracy of fracture over the original GTN model under shear loading conditions. Furthermore, the shear plays a role under meridional tensile stress to accelerate fracture propagation in SPIF processes

Plastic flow and failure in single point incremental forming of PVC sheets

This paper presents an innovative and effective methodology to characterize plastic flow and failure in single point incremental forming (SPIF) of polymers that allows determining the stresses and the accumulated values of ductile damage directly from the experimental values of strain at various positions over the deformed polymer sheets. The approach traces the deformation path of material elements in conical and pyramidal SPIF parts, undergoing linear strain loading paths from beginning until failure, and is built upon the generalization of the analytical framework conditions assumed by Glover et al. [1] to the pressure-sensitive yield surfaces of polymers under incompressible, non-associated, plastic flow. Experimentation in conventional and multi-stage SPIF of Polyvinylchloride (PVC) sheets confirms the effectiveness of the proposed methodology and demonstrates that standard non-coupled damage models currently utilized in sheet metal forming are inapplicable to describe failure in polymers. Instead fracture forming limit lines (FFL’s) should be employed