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Single point incremental forming (SPIF) is more accurate and economical than the conventional forming process for customized products. Majority of the work in SPIF has been carried out on metals. However, polymers are also required to shape. Polycarbonate has wide application in safety glass, bottles, automotive and aircraft industry due to its transparent as well as attractive processing and mechanical properties as compared to other polymeric plastics. In present work, the Polycarbonate (PC) sheet of thickness 1.8 mm is deformed to make a square cup at different angles. Tensile testing is done to analyze the effect of wall angle on the deformed cup. This work illustrates the effect of the SPIF process on material strength in a different directions (vertical and horizontal) of the final deformed product. Tool forces are evaluated using ABAQUS® simulation for SPIF. Numerical simulation approach is used to calculate the fracture energy, which utilizes the force-displacement curve of the specimen and is verified.

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Tensile testing on metastable beta alloy with various microstructures was carried out in this study. Beta 21S is a metastable alloy that exhibits a wide range of material characteristics depending on the processing techniques used. Three different sheets that have been used in this paper which has the same substance but three different microstructures. At a strain rate of 0.001/s, the tensile test was done on a single sheet at five different temperatures. The sheet has developed varied microstructures, the tensile nature of the material varies the alloy’s characteristics. Mechanical characteristics for 400°C, 500°C, 600°C, and 7000°C are described for 21S sheets. The alpha phase sheet elongated at room temperature by 1-3 %, whereas the pure beta phase sheet elongated by 22-24 %. There is a significant improvement in the extension of the sheet with the variation in temperature for the alpha phase. The elongation of the pure beta phase does not alter as the temperature rises. The fracture surface was tested at all temperatures and the optimal temperature for forming the sheet has been determined

In this paper, an innovative way of calculating the Gurson–Tvergaard–Needleman parameter has been developed for AA 6063. AA 6063 is an aluminum alloy comprising the alloying ingredients magnesium and silicon. The Aluminum Association maintains the standard that governs its composition. It has strong mechanical properties and may be heat treated and welded. Image processing technique has been used to calculate the damage constant for the AA 6063. The image of the sample has been taken under a microscope of undeformed and fractured material. Then the images are analyzed using the Open CV tool in a python open-source environment. The initial and final void fraction of the sheet has been calculated. Damage models, particularly the Gurson–Tvergaard–Needleman (GTN) model, are widely used in numerical simulation of material deformations. Each damage model has some constants which must be identified for each material. The direct identification methods are costly and time-consuming. A combination of experimental, numerical simulation and optimization have been used to determine the constants in the current work. Numerical simulation of the dynamic test was performed utilizing the constants obtained from quasi-static experiments. The results showed a high precision in predicting the specimen's profile in the dynamic testing.