Single point incremental forming of a facial implant

Araújo, Rui; Teixeira, Pedro; Montanari, Luciana; Reis, Ana; Silva, M.B.; Martins, P.A.F.

doi:10.1177/0309364613502071

Cited by 45 publications

(26 citation statements)

References 8 publications

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“…Instead, a fracture FLD should be employed. Finite element method, combined with circle grid analysis, was used by Araujo et al [65] in order to explain failure by cracking at the critical geometric features of facial implants and to assist in the overall design of a titanium grade 2 sheet. The fracture limit curves by cracking are characterised by means of a straight line with a slope equal to −0.8 and a maximum drawing angle of approximately 60°.…”

Section: Application Of a Forming Limit Diagrammentioning

confidence: 99%

Review on the influence of process parameters in incremental sheet forming

Gatea

McCartney

2016

Int J Adv Manuf Technol

161

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Incremental sheet forming (ISF) is a relatively new flexible forming process. ISF has excellent adaptability to conventional milling machines and requires minimum use of complex tooling, dies and forming press, which makes the process cost-effective and easy to automate for various applications. In the past two decades, extensive research on ISF has resulted in significant advances being made in fundamental understanding and development of new processing and tooling solutions. However, ISF has yet to be fully implemented to mainstream high-value manufacturing industries due to a number of technical challenges, all of which are directly related to ISF process parameters. This paper aims to provide a detailed review of the current state-of-the-art of ISF processes in terms of its technological capabilities and specific limitations with discussions on the ISF process parameters and their effects on ISF processes. Particular attention is given to the ISF process parameters on the formability, deformation and failure mechanics, springback and accuracy and surface roughness. This leads to a number of recommendations that are considered essential for future research effort.

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Section: Application Of a Forming Limit Diagrammentioning

confidence: 99%

Review on the influence of process parameters in incremental sheet forming

Gatea

McCartney

2016

Int J Adv Manuf Technol

161

View full text Add to dashboard Cite

show abstract

“…Variants include the use of a counter-support tool and use of dies, either full or partial. A number of efforts have been made to manufacture implants and supports for different parts of the human body using ISF such as the skull [2][3][4][5], knee [6], face [7], and ankle support [8] using ISF.…”

Section: Introductionmentioning

confidence: 99%

“…Despite a number of efforts to make medical implant shapes using ISF [2][3][4][5][6][7][8], making these parts with high accuracy has been a problem. Even though Behera et al [2] tried forming implant shapes with high forming angles with improved accuracy, the part made of titanium grade II failed.…”

Section: Introductionmentioning

confidence: 99%

Characterization of shape and dimensional accuracy of incrementally formed titanium sheet parts with intermediate curvatures between two feature types

Behera

Lü

2015

Int J Adv Manuf Technol

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Single point incremental forming (SPIF) is a relatively new manufacturing process that has been recently used to form medical grade titanium sheets for implant devices. However, one limitation of the SPIF process may be characterized by dimensional inaccuracies of the final part as compared with the original designed part model. Elimination of these inaccuracies is critical to forming medical implants to meet required tolerances. Prior work on accuracy characterization has shown that feature behavior is important in predicting accuracy. In this study, a set of basic geometric shapes consisting of ruled and freeform features were formed using SPIF to characterize the dimensional inaccuracies of grade 1 titanium sheet parts. Response surface functions using multivariate adaptive regression splines (MARS) are then generated to model the deviations at individual vertices of the STL model of the part as a function of geometric shape parameters such as curvature, depth, distance to feature borders, wall angle, etc. The generated response functions are further used to predict dimensional deviations in a specific clinical implant case where the curvatures in the part lie between that of ruled features and freeform features. It is shown that a mixed-MARS response surface model using a weighted average of the ruled and freeform surface models can be used for such a case to improve the mean prediction accuracy within ±0.5 mm. The predicted deviations show a reasonable match with the actual formed shape for the implant case and are used to generate optimized tool paths for minimized shape and dimensional inaccuracy. Further, an implant part is then made using the accuracy characterization functions for improved accuracy. The results show an improvement in shape and dimensional accuracy of incrementally formed titanium medical implants.

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“…To enable this, one relatively new manufacturing technique that has come forth is Incremental Sheet Forming (ISF). A number of efforts have been made to manufacture implants and supports for different parts of the human body such as the skull [2][3][4][5], knee [6], face [7], ankle support [8].…”

Section: Introductionmentioning

confidence: 99%

Characterization of shape and dimensional accuracy of incrementally formed titanium sheet parts

Behera

Lü

2015

MATEC Web of Conferences

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Abstract. Single Point Incremental Forming (SPIF) is a relatively new process that has been recently used to manufacture medical grade titanium sheets for implant devices. However, one limitation of the SPIF process may be characterized by dimensional inaccuracies of the final part as compared with the original designed part model. Elimination of these inaccuracies is critical to forming medical implants to meet required tolerances. In this study, a set of basic geometric shapes were formed using SPIF to characterize the dimensional inaccuracies of grade 1 titanium sheet parts. Response surface functions are then generated to model the deviations at individual vertices of the STL model of the part as a function of geometric shape parameters such as curvature, depth, wall angle, etc. The generated response functions are further used to predict dimensional deviations in a specific clinical implant case. The predicted deviations show a reasonable match with the actual formed shape and are used to generate optimized tool paths for minimized shape and dimensional inaccuracy. Further, an implant part is then made using the accuracy characterization functions for improved accuracy. The results show an improvement in shape and dimensional accuracy of incrementally formed titanium medical implants.

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Single point incremental forming of a facial implant

Abstract: Reduce the gap between production engineers and the medical community by presenting a state-of-the-art manufacturing technology to produce low-cost, patient-specific medical implants.

Cited by 45 publications

References 8 publications

Review on the influence of process parameters in incremental sheet forming

Review on the influence of process parameters in incremental sheet forming

Characterization of shape and dimensional accuracy of incrementally formed titanium sheet parts with intermediate curvatures between two feature types

Characterization of shape and dimensional accuracy of incrementally formed titanium sheet parts

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