Simulation-Based Process Design for Asymmetric Single-Point Incremental Forming of Individual Titanium Alloy Hip Cup Prosthesis

Abstract

Advanced manufacturing techniques aimed at implants with high dependability, flexibility, and low manufacturing costs are crucial in meeting the growing demand for high-quality products such as biomedical implants. Incremental sheet forming is a promising flexible manufacturing approach for rapidly prototyping sheet metal components using low-cost tools. Titanium and its alloys are used to shape most biomedical implants because of their superior mechanical qualities, biocompatibility, low weight, and great structural strength. The poor formability of titanium sheets at room temperature, however, limits their widespread use. The goal of this research is to show that the gradual sheet formation of a titanium biomedical implant is possible. The possibility of creative and cost-effective concepts for the manufacture of such complicated shapes with significant wall angles is explored. A numerical simulation based on finite element modeling and a design process tailored for metal forming are used to complete the development. The mean of uniaxial tensile tests with a constant strain rate was used to study the flow behavior of the studied material. To forecast cracks, the obtained flow behavior was modeled using the behavior and failure models.

Selection of Constitutive Material Model for the Finite Element Simulation of Pressure-Assisted Single-Point Incremental Forming

“…Li et al [34] investigated the tool path optimisation of induction heating-assisted SPIF using machine learning. Material formability and surface quality were improved following the optimisation of the tool path and using machine learning; however, noticeable oxidation and alpha layer of the sheet material at heating temperature ~1040 • C were reported, and they were eliminated at ~950 • C. Frikha et al [35] explored incremental forming of grade 2 α titanium for biomedical application (hip cup prostheses). The research suggested a novel multistep process in which a deep drawing was used for the spherical cup part, whereas incremental forming was used for the outer flange part.…”