Introduction
What is Incremental Sheet Forming?
Incremental Sheet Forming (ISF) is a flexible, cost-effective, energy and resource efficient process which is particularly suitable for prototypes and customised products with complex geometries. The process requires no special moulds or dies and no heavy-duty forming equipment, which makes it cost-effective for small batch manufacturing.
Why Use ISF?
Sheet metal forming is widely used in applications ranging from automotive, aerospace and energy to household appliances. However, for each product geometry, conventional forming requires a mould or die. The effects of this constraint include:
Increased manufacturing costs and initial investment.
A prolonged product development cycle.
Ineffectiveness in the production of small batches or customised sheet metal parts.
ISF only requires a simple tool with a hemispherical head, which deforms a sheet of material incrementally as it moves along a predefined toolpath. Toolpaths can be created directly from CAD models, and manufacturing can be performed using a CNC machine.
Research Objectives
A crucial limitation of ISF is that it is generally performed at room temperature, which means it can't manufacture hard-to-form materials with limited room temperature ductility.
The objectives of research at The University of Sheffield are:
To advance ISF processes to manufacturing hard-to-form lightweight alloys by enhancing material formability.
To improve the geometrical accuracy and surface quality of ISF parts.
The overall aim is to advance ISF processes for potential industrial and medical applications.
