Recent Approaches for the Determination of Forming Limits by Necking and Fracture in Sheet Metal Forming

Forming limit diagrams (FLD’s) are used to evaluate the workability of metal sheets. FLD’s provide the failure locus at which plastic instability occurs and localized necking develops (commonly designated as the forming limit curve - FLC), and the failure loci at the onset of fracture by tension (FFL) or by in-plane shear (SFFL). The interest of metal formers in controlling localized necking is understandable because the consequence of plastic instability is an undesirable surface blemish in components. However, because under certain loading conditions fracture can precede necking in sheet metal forming processes, there is a growing interest in characterizing the forming limits by necking and fracture in the FLD’s. This paper gathers together a number of recently developed methodologies for detecting the onset of local necking and fracture by in-plane tension or in-plane shear, and discusses their applicability to determine experimentally the FLC’s, FFL’s and SFFL’s.Ministerio de Economía y Competitividad DPI2012-3291

Single point incremental forming of polymers

AbstractThe aim of the present paper is to evaluate the possibility of producing low-cost, small-batch, polymer sheet components by means of single point incremental forming (SPIF) at room temperature. During the research work, five different thermoplastic materials were incrementally formed into cones with an increasing wall angle on a conventional CNC milling machine. In designed experiments, significant process parameters were found, and influential material properties were identified. The experimental results confirm that SPIF of commercial polymer sheets at room temperature has potential for the manufacture of complex parts with very high depths

Tube Expansion by Single Point Incremental Forming: An Experimental and Numerical Investigation

In this paper, we revisit the formability of tube expansion by single point incremental forming to account for the material strain hardening and the non-proportional loading paths that were not taken into consideration in a previously published analytical model of the process built upon a rigid perfectly plastic material. The objective is to provide a new insight on the reason why the critical strains at failure of tube expansion by single point incremental forming are far superior to those of conventional tube expansion by rigid tapered conical punches. For this purpose, we replaced the stress triaxiality ratio that is responsible for the accumulation of damage and cracking by tension in monotonic, proportional loading paths, by integral forms of the stress triaxiality ratio that are more adequate for the non-proportional paths resulting from the loading and unloading cycles of incremental tube expansion. Experimental and numerical simulation results plotted in the effective strain vs. stress triaxiality space confirm the validity of the new damage accumulation approach for handling the non-proportional loading paths that oscillate cyclically from shearing to biaxial stretching, as the single point hemispherical tool approaches, contacts and moves away from a specific location of the incrementally expanded tube surface.Junta de Andalucía (Consejería de Economía y Conocimiento) US-1263138Fundação para a Ciência e da Tecnologia of Portugal UIDB/50022/202

Assembly of lightweight sandwich panels through joining by forming

This paper is focused on the assembly of lightweight sandwich panels built upon the patented ‘Opencell’ structure concept. The objective is to investigate the possibility of joining the connection members of the core to the adjoining skin sheet by plastic deformation at ambient temperature, instead of welding or adhesive bonding. The methodology draws from earlier developments of the authors in joining by forming using the mortise-and-tenon concept to experimentation and finite element modelling of the assembly process in unit cells that are representative of the sandwich panels. It is shown that replacing welding by joining by forming allows fabricating sandwich panels from sheet materials that are difficult or impossible to weld while preventing thermal cycles that are responsible for causing metallurgical changes, distortions, and residual stresses. Replacing adhesive bonding by joining by forming circumvents the need of surface preparation, time for the adhesive to cure and environmental compliance, among other requirementsinfo:eu-repo/semantics/publishedVersio

Reducing the environmental impact of surgery on a global scale: systematic review and co-prioritization with healthcare workers in 132 countries

Background Healthcare cannot achieve net-zero carbon without addressing operating theatres. The aim of this study was to prioritize feasible interventions to reduce the environmental impact of operating theatres. Methods This study adopted a four-phase Delphi consensus co-prioritization methodology. In phase 1, a systematic review of published interventions and global consultation of perioperative healthcare professionals were used to longlist interventions. In phase 2, iterative thematic analysis consolidated comparable interventions into a shortlist. In phase 3, the shortlist was co-prioritized based on patient and clinician views on acceptability, feasibility, and safety. In phase 4, ranked lists of interventions were presented by their relevance to high-income countries and low–middle-income countries. Results In phase 1, 43 interventions were identified, which had low uptake in practice according to 3042 professionals globally. In phase 2, a shortlist of 15 intervention domains was generated. In phase 3, interventions were deemed acceptable for more than 90 per cent of patients except for reducing general anaesthesia (84 per cent) and re-sterilization of ‘single-use’ consumables (86 per cent). In phase 4, the top three shortlisted interventions for high-income countries were: introducing recycling; reducing use of anaesthetic gases; and appropriate clinical waste processing. In phase 4, the top three shortlisted interventions for low–middle-income countries were: introducing reusable surgical devices; reducing use of consumables; and reducing the use of general anaesthesia. Conclusion This is a step toward environmentally sustainable operating environments with actionable interventions applicable to both high– and low–middle–income countries

Double-sided self-pierce riveting of polymer sheets

This paper is focused on extending the applicability domain of double-sided self-pierce riveting to the production of invisible lap joints in polymer sheets. The presentation draws from the working principle and identification of the main process parameters to aspects of design and fabrication of the tubular rivets and lap joints. The experimental work is carried out in polyvinylchloride sheets and stainless-steel tubular rivets and is supported by finite element modelling. It is shown that double-sided self-pierce riveting with adequate geometry of the tubular rivets can be used effectively to produce invisible lap joints in polymer sheets at room temperature with neither surface preparation and pre-drilling of holes nor material protrusions above and below the sheets after joining

Innovative cold joining technologies based on tube forming

This paper is focused on innovative cold joining technologies for connecting tubes and fixing tubes to sheets. The proposed technologies are based on the utilization of plastic instability waves in thin-walled tubes subjected to axial compression and may be seen as an alternative to conventional joining technologies based on mechanical fixing with fasteners, welding and structural adhesive bonding. Besides allowing connecting dissimilar materials and being successfully employed in fixture conditions that are difficult and costly to achieve by means of conventional joining the new proposed technologies also cope with the growing concerns on the demand, lifecycle and recycling of materials