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 xiiiList of Contributors xviiPreface xxi1 Incremental Sheet Forming – A State-of-Art Review 1K. S. Rudramamba, M. Rami Reddy, and Mamatha Nakka1.1 Introduction to Incremental Sheet Forming 11.2 Incremental Sheet Forming Process 21.2.1 Single-Point Incremental Sheet Forming (SPISF) 41.2.2 Two-Point Incremental Sheet Forming (TPISF) 41.2.3 Double-Sided Incremental Forming 51.2.4 Hybrid Incremental Forming 51.2.5 Thermal-Assisted Incremental Forming (TAIF) 61.3 Materials for Incremental Sheet Forming 71.4 Formability Limits with AI Implementation 91.5 Conclusions and Future Scope 9References 102 Classification of Incremental Sheet Forming 15Rupesh Kumar and Vikas Kumar2.1 Introduction 152.1.1 History 162.2 Classification of ISF 172.2.1 Classification Based on Forming Methods of ISF 172.2.1.1 SPIF 182.2.1.2 TPIF 192.2.1.3 MPIF 202.2.1.4 Hybrid-ISF 202.2.2 Classification Based on Forming Tools of ISF 202.2.3 Classification Based on Forming Path of ISF 212.2.4 Classification Based on Forming Machine of ISF 222.2.5 Classification Based on Hot Forming of ISF 232.3 Conclusion 252.4 Future Work 25References 253 A Review on Effect of Computer-Aided Machining Parameters in Incremental Sheet Forming 29Rupesh Kumar, Vikas Kumar, and Ajay Kumar3.1 Introduction 293.2 Process Parameters 293.2.1 Effects of Process Parameters on Surface Roughness 303.2.2 Effect of Process Parameters on Forming Force 313.2.3 Effect of Process Parameters on Formability 353.2.4 Effect of Process Parameters on Thickness Distribution 413.2.5 Effect of Process Parameters on Dimensional Accuracy 423.2.6 Effect of Process Parameters on the Processing Time 473.2.7 Effect of Process Parameters on Energy Consumption 483.3 Conclusion 493.4 Future Work 51Funding Statement 52Conflicts of Interest 52Acknowledgment 52References 534 Equipment and Operative for Industrializing the SPIF of Ti-6Al-4V 59Mikel Ortiz, Mildred Puerto, Antonio Rubio, Maite Ortiz de Zarate, Edurne Iriondo, and Mariluz Penalva4.1 Introduction 594.2 Materials and Methods 604.2.1 Original Equipment 604.2.2 Methodology 624.3 Results and Discussion 634.3.1 Hot SPIF System 634.3.1.1 Forming Temperatures Range 634.3.1.2 Concept 654.3.1.3 Heating Units and Control 664.3.1.4 Forming Tool 724.3.1.5 Costs Assessment 724.3.2 Hot SPIF of Ti-6Al-4V 754.3.2.1 Overview 754.3.2.2 Temperature Cycles 764.3.2.3 Practices for Higher Accuracy 794.3.2.4 Subsequent Operations 834.4 Conclusion 89References 905 Texture Development During Incremental Sheet Forming (ISF): A State-of-the-Art Review 93Tushar R. Dandekar and Rajesh K. Khatirkar5.1 Introduction 935.2 Crystallographic Texture 945.2.1 Introduction to Crystallographic Texture 945.2.2 Texture Evolution During ISF 965.2.2.1 Texture Evolution During ISF of Aluminum Alloys 965.2.2.2 Texture Development in ISF of AA1050 Alloy in Three Stages of SPIF 975.3 Microstructure Evolution During ISF 1025.3.1 Microstructures 1025.3.2 Microstructure Evolution During ISF in Various Materials 1035.3.2.1 AA5052 Aluminum Alloy 1035.3.2.2 Dual Phase (DP590) Steel 1055.4 Deformation Mechanism During ISF 1075.4.1 Membrane Strain 1075.4.2 Shear Deformation 1085.4.3 Bending Under Tension (BUT) 1105.5 Future Scope 1115.6 Summary 111Abbreviations 112References 1126 Analyses of Stress and Forces in Single-Point Incremental Sheet Metal Forming 117Swapnil Deokar and Prashant K. Jain6.1 Introduction 1176.1.1 Classification of ISF Based on Forming Methods 1186.2 Experimental Setup 1196.2.1 Machining Parameters in ISF 1196.2.2 Tool Path Strategies 1206.3 FE Analysis of ISF 1216.3.1 Analysis of Stress on Parts 1216.3.2 Forces Behavior in ISF 1226.3.3 Stress Effect on Thinning Part 1226.3.4 Applications of ISF 1246.3.5 Result and Discussion 1246.3.5.1 Stress Behavior 1246.3.5.2 Force Behavior 1256.3.5.3 Thinning Characteristics 1256.4 Conclusion 1266.5 Future work 126References 1267 Finite Element Simulation Approach in Incremental Sheet Forming Process 129Archana Jaglan, Namrata Dogra, Ajay Kumar, and Parveen Kumar7.1 Introduction 1297.2 Finite Element Simulation 1307.2.1 Definition 1307.2.2 History of Finite Element Method 1317.2.3 Various Software Used for Finite Element Simulation in Incremental Sheet Forming Process 1337.2.4 Categories and Types of Finite Element Method Simulation 1347.2.5 Application of Finite Element Simulation in Incremental Sheet Forming Process 1357.2.6 Advantages of Finite Element Simulation in Incremental Sheet Forming Process 1377.3 Conclusion 138References 1388 Detection of Defect in Sheet Metal Industry: An Implication of Fault Tree Analysis 141Soumyajit Das8.1 Introduction 1418.2 Methodology 1428.2.1 Data Collection 1428.2.2 Problem Description 1428.2.3 FMEA Analysis 1438.2.4 Fault Tree Analysis 1438.2.5 Fishbone Diagram 1458.3 Result and Analysis 1468.4 Discussion 1488.5 Conclusion 149References 1509 Integration of IoT, Fog- and Cloud-Based Computing-Oriented Communication Protocols in Smart Sheet Forming 151Monisha Awasthi, Anamika Rana, Sushma Malik, and Ankur Goel9.1 Introduction 1519.2 Background 1549.3 Communication Protocol Overview 1569.3.1 HTTP: Hyper Text Transfer Protocol 1579.3.2 CoAP: Constrained Application Protocols 1579.3.3 MQTT: MQ Telemetry Transport 1589.3.4 DDS: Data Distribution Services 1599.3.5 AMQP: Advanced Message Queuing Protocol 1609.3.6 XMPP: Extensible Messaging and Presence Protocol 1609.4 Comparative Study of Communication Protocol for IoT Premise 1619.5 IOT, FOG, and CLOUD (ITCFBC) Are Interrelated 1629.6 Challenges and Related Issues 1629.7 Conclusion and Future Scope 164References 16410 Blockchain for the Internet of Things and Industry 4.0 Application 167Dhirendra Siddharth, Dilip Kumar Jang Bahadur Saini, and Sunil Kumar10.1 Introduction 16710.2 Blockchain’s Application in a Wide Range of Industries 16810.2.1 Supply Chain 16810.2.2 Financial Transactions 16810.2.3 Encryption of Data 16810.2.4 Product Information 16810.2.5 Peer-to-Peer Trading 16810.3 Blockchain Plays in the Future of Our Economy 16910.3.1 The End of Corruption 16910.3.2 Integrity 16910.3.3 Contracts Without the Middle Person 17010.3.4 No Financial Stand 17010.3.5 Easier Management Without Analytics 17010.4 Changes in Society Using the Internet of Things and Blockchain 17010.4.1 Changes Through Blockchain 17010.4.2 Changes Through the Internet of Things 17110.5 Blockchain Transform Industries and the Economy 17110.6 Blockchain Support Swinburne’s Industry 4.0 Strategy 17210.7 Blockchain Technology’s Impact on the Digital Economy 17310.7.1 Changes in the Architecture 17310.7.2 Networking and Verification Expenses Are Reduced 17310.7.3 Automation 17410.8 Chains Are Being Revolutionized by Blockchain Technology 17410.8.1 Manual Procedures Are Being Replaced 17510.8.2 Increased Traceability 17510.8.3 Reliability and Trustworthiness Are Being Improved 17510.8.4 Processing Transactions in a Timely and Effective Manner 17510.9 Businesses That Use Blockchain Technology 17510.9.1 Blockchain Can Boost Supply Chain Value 17510.10 Real-World Use Cases for dApps and Smart Contracts 17610.10.1 Financial Use Cases for Smart Contracts 17610.10.2 Gaming Using Blockchain Technology: NFTs and Smart Contracts 17710.10.3 Blockchain and Smart Contracts in the Legal Industry 17710.10.4 Real Estate and Blockchain 17710.10.5 Creating DAOs with Smart Contracts for Corporate Structures 17810.10.6 Smart Contracts in Emerging Technology Applications 17810.10.7 Smart Contracts’ Potential Benefits in Other Industries 17810.11 Blockchain Is About to Revolutionize the Courtroom 17910.11.1 Enhanced Security Levels 17910.11.2 Better Agreements 18010.12 Conclusion 180References 18011 Experimental Study on the Fabrication of Plain Weave Copper Strips Mesh-Embedded Hybrid Composite and Its Benefits Over Traditional Sheet Metal 183Ravindra Chopra, Mukesh Kumar, and Nahid Akhtar11.1 Introduction 18311.1.1 Composite Material: Overview 18311.1.2 Classification of Composite Materials 18311.1.3 Fiber-Reinforced Plastic (FRP) Composite Material 18311.1.4 Advantages of Composites 18511.1.5 Why Composites Are Replacing Traditional Sheet Metals 18511.1.5.1 High Degree of Strength 18511.1.5.2 Longer Life Span 18611.1.5.3 Composites Allow New Design Possibilities 18611.1.6 Applications of Hybrid Composites Over Sheet Metals 18611.1.7 Failure Modes 18611.1.8 Concerns About Disposal and Reuse 18611.1.9 Problem Definition 18711.1.10 Layout of the Project 18711.1.11 Research Objectives 18711.1.12 Research Application 18711.2 Proposed Methodology 18811.3 Experimental Procedure 18811.3.1 Raw Materials 18811.3.1.1 E-Glass Fiber (CSM) 19011.3.1.2 Epoxy Resin (Araldite LY556) 19111.3.1.3 Hardener (Aradur HY951) 19111.3.1.4 Flat Copper Sheet 19111.3.2 Mold Preparation 19211.3.3 Releasing Agent 19311.3.4 Plain Weave Copper Strips Mesh Preparation 19311.3.5 Composite Preparation 19311.3.6 De-Molding Process 19611.3.7 Mechanical and Physical Studies of GFRP and Hybrid Composites 19611.3.7.1 Tensile Strength Testing 19711.3.7.2 Flexural Strength Testing 20111.3.7.3 Izod Impact Strength Testing 20211.3.7.4 Shore D Hardness Testing 20211.3.7.5 Density Testing 20311.4 Results and Discussions 20511.4.1 Tensile Strength 20511.4.2 Flexural Strength 20611.4.3 Izod Impact Strength 20711.4.4 Shore D Hardness 20811.4.5 Density 20911.5 Conclusions 21011.6 Future Scope 211References 21112 Application of Reconfigurable System Thinking in Reconfigurable Bending Machine and Assembly Systems 213Khumbulani Mpofu, Boitumelo Innocent Ramatsetse, Olasumbo Ayodeji Makinde, and Olayinka Mohammed Olabanji12.1 Introduction: Background and Overview 21312.1.1 Definition of Key Terms 21312.2 Description of Machining, Bending, and Assembly Processes 21412.3 Related Works on Manufacturing Systems 21412.4 Conventional Sheet Metal Bending and Assembly System Technologies 21512.4.1 Conventional Sheet Metal Bending Technologies 21512.5 Trends and Evolution of Manufacturing System Paradigms 21812.5.1 Classification of Press Brake Machines 21812.5.2 Classification of Assembly System Technologies 22112.5.2.1 Assembly Systems and Their Mode of Configuration 22212.5.2.2 Assembly Systems Based on Their Mode of Operation 22212.5.3 Application of RMS in Sheet Metal Bending Process 22312.6 Case Studies for Application of RMS in Bending Operations 22412.6.1 Description RBPM Machine 22412.6.2 RMS Characteristics for RBPM Machine 22612.7 Scalability Planning for RMS 22712.7.1 Convertibility Assessment for Reconfigurable Manufacturing Systems 22912.7.1.1 Incremental Conversion 23012.7.1.2 Routing Connections 23012.7.1.3 Routing Modules 23012.8 Modularity Assessment for Reconfigurable Systems 23612.9 Case Studies for Application of RMS in Assembly Operations 23912.9.1 Description Reconfigurable Assembly Fixture 23912.9.2 RMS Characteristics for RAF Machine 24012.10 Conclusions 242References 24313 Application of Incremental Sheet Forming (ISF) Toward Biomedical and Medical Implants 247Ajay Kumar, Parveen Kumar, Namrata Dogra, and Archana Jaglan13.1 Introduction 24713.1.1 Conventional Manufacturing Process 24713.1.2 Incremental Sheet Forming 24913.2 Classification of ISF 24913.3 Process Parameters of ISF 25013.3.1 Tool Path 25113.3.2 Tool Size 25113.3.3 Tool Rotation 25113.3.4 Sheet Material 25113.3.5 Forming Speed 25113.3.6 Step Size 25213.4 Materials for Fabrication of Implants 25213.5 Methods of Implant Manufacturing 25313.6 Applications of ISF Process 25313.6.1 Cranial Implant 25313.6.2 Facial Implant 25513.6.3 Denture Base 25713.6.4 Knee Prosthesis 25713.7 Challenges of ISF Process 25913.8 Future Scope of ISF 26013.9 Conclusion 261References 261Index 265