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Procedia Manufacturing 00 (2018) 000–000
Procedia Manufacturing 00 (2018) 000–000 www.elsevier.com/locate/procedia
www.elsevier.com/locate/procedia
Procedia Manufacturing 29 (2019) 21–27
Procedia Manufacturing 00 (2017) 000–000
www.elsevier.com/locate/procedia
18th International Conference on Sheet Metal, SHEMET 2019
18th International Conference on Sheet Metal, SHEMET 2019
Heat supported single point incremental forming of hybrid laminates for
Heat supported single point incremental forming of hybrid laminates for
orthopedic applications
orthopedic
Manufacturing Engineering Society applications
International Conference 2017, MESIC 2017, 28-30 June
Amar AL-Obaidia,* 2017, Vigo (Pontevedra),
a Spaina b
a,*, Alexander Grafa, Verena Kräusela and Maik Trautmannb
Amar AL-Obaidi , Alexander Graf , Verena Kräusel and Maik Trautmann
Institute of Machine Tools and Production Processes IWP, Technische Universität Chemnitz, Professorship of Forming and Joining UFF, Chemnitz Germany
a

Costing
Institute of Machine
a
models
Institute
b Tools
of Materials forandProcesses
and Production
Science capacityIWP, IWW,
Engineering optimization
Technische
Chair Universität Chemnitz,
of Composites inCompounds,
and Material Industry
Professorship of Forming 4.0:
and Joining
Technische Trade-off
UFF,
Universität Chemnitz Germany
Chemnitz
Institute of Materials Science and Engineering IWW, Chair of Composites and Material Compounds, Technische Universität Chemnitz
b

between used capacity and operational efficiency

Abstract
Abstract
a a,* b b
Ecofriendly composite fibers A.areSantana
increasingly, P. Afonso
applied , A. Zanin
as a substitutional material, R. Wernke
instead of the expensive carbon fibers. Within
Ecofriendly composite fibers are increasingly
this context a hybrid laminate was developed applied as a substitutional material instead of the expensive
combining an aluminum sheet with basalt fiber-reinforced thermoplastic carbon fibers. Within
polyamide
a
this context a hybrid laminate was University
developed of Minho,
combining an 4800-058 Guimarães,
aluminum sheet withPortugal
basalt fiber-reinforced thermoplastic polyamide
6 (BFRP). As a condition for the formability bit is necessary to transform the polyamide matrix into a semi-fluidized state. Therefore,
6a single
(BFRP). As aincremental
point condition for the formability
forming itUnochapecó,
is necessary
process supported
89809-000
with to
Chapecó,
hottransform thewas
air heating
SC, Brazil matrix into a semi-fluidized state. Therefore,
polyamide
utilized to form the hybrid laminate into the desired
ashape.
singleDuring
point incremental forming process supported with hot air heating
the forming process the composite was inserted between two metal was utilized toand
sheets form theTeflon
two hybridlayers
laminate intowere
which the desired
used to
shape. During the forming process the composite was inserted between two metal sheets and two Teflon
improve the sliding of the hybrid laminate during the forming operation. Furthermore, the metal sheets were used to ensure layers which were used an
to
improve
efficient the sliding and
processing of the hybrid
protect thelaminate
hybrid during the
laminate forming
against wear operation.
caused Furthermore,
by friction the metal
between the sheets tool
forming wereand
usedthe tocomposite.
ensure an
Abstract
efficient processing and out
protect themelted
hybridpolymer
laminatematrix
against
In addition, the squeeze of the outwear caused
of the hybridbylaminate
friction between the forming
was reduced. tool of
The results andthetheinvestigation
composite.
In addition, the squeeze out of the melted polymer matrix out of the hybrid laminate was reduced. The
of the experimental process parameters are presented. The proposed method offers the possibility to manufacture individualresults of the investigation
Under
of the conceptprocess
the experimental of "Industry
parameters 4.0",
are production
presented. The processes
proposedwill be pushed
method offers thetopossibility
be increasingly interconnected,
to manufacture individual
orthopedic products or prototypes of medical implants.
information based on a real time basis and,
orthopedic products or prototypes of medical implants. necessarily, much more efficient. In this context, capacity optimization
goes© beyond
2018 the traditional aim of by capacity maximization, contributing also for organization’s profitability and value.
© 2019 The The Authors.
Authors. Published
Published by Elsevier Elsevier
B.V. B.V.
©
Indeed,2018
This The
lean Authors.
management Publishedand by Elsevier
continuous B.V.improvementlicense (approaches suggest capacity optimization ) instead of
This is anisopen
an open
accessaccess
articlearticle under
under the CC the CC BY-NC-ND
BY-NC-ND https://creativecommons.org/licenses/by-nc-nd/4.0/
license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
This is an and
maximization.
Selection open access
The study
peer-reviewarticle
of under
capacity
under the optimization
CC BY-NC-ND
responsibility of the andlicense (committee
costing
organizing https://creativecommons.org/licenses/by-nc-nd/4.0/
models is
of an important
SHEMET 2019. research topic )that deserves
Selection and peer-review under responsibility of the organizing committee of SHEMET 2019.
Selection and
contributions peer-review
from both theunder responsibility
practical of the organizing
and theoretical committee
perspectives. Thisofpaper
SHEMET 2019.
presents and discusses a mathematical
Keywords:
model forHybrid laminate;
capacity Basalt fiber reinforced
management basedpolamer; Single pointcosting
on different incremental forming(ABC and TDABC). A generic model has been
models
Keywords: Hybrid laminate; Basalt fiber reinforced polamer; Single point incremental forming
developed and it was used to analyze idle capacity and to design strategies towards the maximization of organization’s
value. The trade-off capacity maximization vs operational efficiency is highlighted and it is shown that capacity
1. Introduction
1. Introduction
optimization might hide operational inefficiency.
© 2017
The The Authors. Published by
carbon-fiber-reinforced Elsevier(CFRP)
polymer B.V. and the glass-fiber-reinforced polymer (GFRP) are mostly used in the
The carbon-fiber-reinforced
Peer-review
manufacturing under responsibility
of lightweight polymer
of (CFRP)
the scientific
constructions and high
committee
due to their theofglass-fiber-reinforced
the Manufacturing
strength, polymerandSociety
Engineering
corrosion resistance (GFRP) are lightweight
mostly Conference
International
extremely used in the
compared
manufacturing
2017. of lightweight constructions due to their high strength, corrosion resistance and extremely
with metals. The composite materials are widely implemented in industrial applications like in airplanes, machine constructions,lightweight compared
with
marinemetals. The composite
structures, materials
civil engineering are widelyindustry
automobile implemented
and in in industrial
medical applications
applications. like in there
Basically, airplanes, machine
are two constructions,
types of composites
marine
Keywords:
accordingstructures,
Cost civilABC;
Models;
to the engineering
combining matrixautomobile
TDABC; Capacity industry and
Management;
type: thermoplastic IdleinCapacity;
and medicalOperational
applications.
thermosetting Basically,
Efficiency
structures. there the
In addition, are composite
two types of composites
materials are
according
extensivelytoused
the incombining
biomedicalmatrix type: thermoplastic
applications and thermosetting
[1] and in medical orthopedics [2].structures. In addition,
The utilization the composite
of implants is favored materials are
for prototype
extensively used in biomedical
production methods. The most applications [1] andforming
challenges during in medical orthopedicslaminates
the composite [2]. The utilization of implants
are poor rigidity, is favored
non-clear forproperties,
plastic prototype
production
to formmethods.
1. Introduction
hard The most
into complex challenges
shapes and highduring forming
sensitivity the composite
during machining.laminates are poor
Furthermore, rigidity, non-clear
the manufacturing plasticby
processes properties,
molding
hard to form into complex shapes and high sensitivity during machining. Furthermore, the manufacturing processes by molding
The cost of idle capacity is a fundamental information for companies and their management of extreme importance
in modern production systems. In general, it is defined as unused capacity or production potential and can be measured
in several ways: tons of production, available hours of manufacturing, etc. The management of the idle capacity
*
** Corresponding
Paulo Afonso.author. Tel.: +49371531-34693
Tel.: +351 253 510 761; fax: +351 253 604 741
E-mail
E-mailaddress:
Corresponding author.
address: Tel.: +49371531-34693
amar-baker-salim.al-obaidi@s2013.tu-chemnitz.de
psafonso@dps.uminho.pt
E-mail address: amar-baker-salim.al-obaidi@s2013.tu-chemnitz.de
2351-9789 © 2018 The Authors. Published by Elsevier B.V.
2351-9789
2351-9789 ©©2018
2017The
The Authors.
Authors. Published
Published by Elsevier
by Elsevier B.V. B.V.
This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
2351-9789
Peer-review
This is an and
Selection ©
open 2019responsibility
under
access The Authors.
article
peer-review under
under the Published
of the
CC of theby
scientific
BY-NC-ND
responsibility Elsevier
committee
license
organizing B.V.
of the Manufacturing Engineering Society International Conference 2017.
(https://creativecommons.org/licenses/by-nc-nd/4.0/)
committee of SHEMET 2019.
This is an
Selection andopen accessunder
peer-review article under theofCC
responsibility BY-NC-ND
the organizing licenseof(https://creativecommons.org/licenses/by-nc-nd/4.0/)
committee SHEMET 2019.
Selection and peer-review under responsibility of the organizing committee of SHEMET 2019.
10.1016/j.promfg.2019.02.101
222 Amar Al-Obaidi
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[3], autoclave [4] or direct continuous film stacking [5], 3D printing [6] and fiber foil taping as experimented in [7] were used only
for mass production processes. One of these methods is hot forming of thermoplastic composites by V-bending, embossing and hot
bending as investigated in [8]. A global heating process comprises induction heating and conductive heaters. In another trial [9] a
deep drawing tool was used by applying conductive heaters to increase the fiber temperature in the blank holder inside the die
assembly. Moreover, the composite fiber structure was firstly heated in an external IR oven, then transferred to a deep drawing die
mounted to a hydraulic press [10]. The previously stated investigations using either the forming or the heating method cannot
feasibly be used for prototype production processes due to the high cost. These costs were appeared by the fixed tool shapes related
to the heating process or transportation of the workpiece from oven to the tool, especially by utilizing the basic matrix thermoplastic
with fibers.
The development of the CAD/CAM systems and automated CNC machines are the basis for introducing single point incremental
forming (SPIF) for a prototype manufacturing process. In recent years, SPIF has been linked with a heating source to heat up and
form metals by hot forming process [11]. In addition, the heating of the sheet in SPIF either all over or locally applied. As a global
heating method was proposed by [12] or local heating as described in [13]. Furthermore, a PVC polymer sheet was also formed at
room temperature by SPIF as demonstrated in [14]. Due to the fact that the recycling and production methods of CFRP and GFRP
are very costly therefore a new material of organic composite material was developed to substitute the CFRP and GFRP [15]. An
organic naturally material composite basalt fiber reinforced thermoplastic polymer (BFRP) is made of basalt fibers combined with
polyamide 6 (PA 6). A (BFRP) was impeded between 2 sheet metals to form a laminate composite structure. Up to now, the
laminate composite structures have only been formed by conventional forming methods as listed in the above literature. A new
SPIF process is suggested to form the solidified thermoplastic basalt fiber reinforced polymer composing heating up by hot air and
simultaneously formed with SPIF process to achieve a conical shape. After that, it was left to solidify.
The overall aim of this work is to successfully form the BFRP laminate into another shape by applying the SPIF process, thereby
directly forming components that match the final part shape. So the directly formed profiles can easily be applied in the production
of human implants, prosthetics and orthotics. The minimization of the implants production process will reduce the cost of implants
immensely. Currently, for example, an elaborately manufactured form is usually required for the production of individual orthotics
by manual laminating of thermoset plastic prepregs.
Table 1. Mechanical properties of BFRP of 0.17 mm layer thickness
Mechanical properties value
E-Module [GPa] 47
Ultimate tensile strength [MPa] 845
Flexural modulus [GPa] 44
Bending strength [MPa] 880
density [g/cm³] 2.01
Elongation till fracture [%] 3.1

2. Basalt fiber reinforced thermoplastic polymer laminate

The BFRP laminate consists basically of basalt fiber fabric and aluminum sheets. The basalt fibers were immersed in a matrix
of thermoplastic PA6. In addition, the mechanical properties of basalt fibers can be seen clearly in Table 1.
The aluminum sheets applied in the BFRP laminate structure have a thickness of 0.3 mm of EN AW-5754 H24 alloy.
Furthermore, the aluminum sheet surface was sandblasted of peak-to-peak roughness RZ = 27 µm. Two types of laminate structures
were investigated in the experiments. The first one called type I contains two aluminum sheets and the BFRP was sandwiched
between them as can be seen in (Fig. 1 type I). Whereas, the second called type II and contained only one aluminum sheet that

Fig. 1. BFRP laminates structures that applied in the experiments.

 Amar Al-Obaidi/
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sandwiched between two BFRP as illustrated in (Fig. 1 Type II). On the other hand, the laminate structure lay-up was of
unidirectional symmetrical laminate with (0/-45/90/+45/0)S of thermoplastic prepregs of basalt fibers and PA6 layers. Both types
of laminates were manufactured in Cetex Institut für Textil- und Verarbeitungsmaschinen gemeinnützige GmbH by compression
thermoplastic method. Basalt fibers were produced by DFB-DEUTSCH BASALT FASER GmbH. The full preparation and
production method of the BFRP was introduced by [7].

3. Experimental procedure and conditions

3.1. Hot V-bending

The characterization of the laminate parameters during hot forming was utilized by hot V-bending forming process. It is not
possible to bend the BFRP laminate at room temperature due to delamination and cracks propagated in the laminates structure [16].
Therefore, a hot bending process was utilized. A specific hot V-bending tool was used in the process as indicated in Fig. 2. The V-
bending process was carried out by a universal testing machine of 150 kN manufactured by Hegewald & Peschke company. The
V-bending tool that utilized in the experiment was isolated by a glass-fiber-reinforced thermoset plates to keep the heat transfer to
minimum values. Therefore, the punch and die were isolated and heated by heating cartridges. In addition, to find the effect of tool
radius on the formability of BFRP laminate three different tool were investigated and of 2, 6 and 10 mm radius. The punch and die
shown in Fig. 2 can be easily changed for the applied V-bending tool assembly. At first, the BFRP laminate was heated in an oven
between 230 °C to 300 °C with soaking time of 10 minutes to ensure the homogeneity of heat distribution over the sample volume.
The BFRP laminate sample was of 20 mm in width, 2.5 mm thickness and 150 mm in length. Each experiment was repeated three
times to insure the stability of the results.

3.2. Hot SPIF process of BFRP Laminate

The experiment set-up utilized in the investigations consists principally of a CNC milling machine, forming tool, a heating
device, clamping fixture and isolating chamber. A hot air blower mounted next to the holding device, as shown in Fig. 3, was used
to heat the laminate structure during forming.. The heating device consists of resistance heaters with an air blower which drives the
hot air through a pipe to the holding fixture. Furthermore, the heating temperature was regulated by an analog controller connected
with the thermocouple. At the same time, the thermocouple is welded with the supporting steel sheet under the BFRP laminate that
has to be formed. A type MISTRAL 6 from Leister Technologies AG, which can generate a maximum heating temperature of 650
°C, was used as the hot-air heater. In addition, the maximum heating power provided is 4.5 kW. Moreover, the heating process of
the BFRP laminate was adjusted by an isolated clamping frame , hot chamber and supporting plates. The insulation material was
made of glass-fiber-reinforced thermal resistance clamps with a thickness of 15 mm, which can withstand the compressive forces
of the clamping screws. On the other hand, the hot chamber was isolated by a box made of silicate material to reduce the heat
transfer between the laminate and the outer environment.

Fig. 2. V-bending tool assymble.

424 Amar Al-Obaidi
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Fig. 3. experiment set-up used in the investigations.

The upper BFRP laminate temperature was senced by an IR-camera of (InfraTec type VarioCAM®) with a measuring range
(frpm -40 to 1000 °C). The IR-camera was used to measure the upper surface heating temperature. In addition, a calibration
tolarance of ± 5 °C was calculated between the thermocouple and the heating temperatures measured by the IR-camera. Both
laminate types I and II were protected on the upper side (forming tool side) with a steel sheet which called dummy sheet of 1.5 mm
thickness. Furthermore, the dummy sheet was utilized to protect the laminate from frictional distortion caused by the forming tool.
It is worth to note that in [8] the dummy sheet was also applied to protect the composite material during forming. In order to
enhance the IR-camera measuring accuracy and improve the emissivity of the dummy steel sheet, a graphite and grease mixture
HYKOGEEN® PASTE 712 made by FUCHS LUBRITECH GmbH was applied in the experiments. Moreover, the graphite
mixture was also served as a lubricant to reduce the friction between the dummy steel sheet and forming tool.
At the same time, the BFRP laminate type II was embedded between two supporting metal sheets and two Teflon (PTFE
polytetrafluoroethylene) sheets 0.5 mm thick . Furthermore, the Teflon sheets were applied to prevent the adhesion between the
dummy sheet surface and the type II laminate surface during hot forming. Consequently, the Teflon sheets were utilized to permit
the sliding during forming by allowing the specified shape to be formed with an acceptable level of flexibility. The sliding action
was indicated by [17] which was the sliding of the basalt fibers between the melted PA 6 matrix and aluminum sheet laminate
supporting the forming process. Moreover, a thin aluminum sheet AlMg3 with a thickness of 0.5 mm and fixed on the bottom side
was used to protect the PA 6 matrix from excessive heating, which caused the polymer to melt. As a result, the arrangement of the
type II laminate workpiece combination from the bottom to the top tool side is as follows: aluminum sheet, Teflon, BFRP laminate,
Teflon, and steel sheet. On the other hand, the forming tool utilized in the experiment was made of tungsten carbide (KXF material),
the same as that was used by [18]. The parameters of the SPIF process were listed in Table 2. The tool path applied in the experiment
was generated by an ESPRIT CAM program under license of Future-CAM GmbH.
Table 2: Hot SPIF parameters.
parameter value
Incremental step down depth ΔZ 25 mm
Feed rate 560 mm/min
Tool diameter 12 mm
Formed shape diameter Cone
Part outer diameter 100 mm
Tool path Spiral
Designed shape wall angle From 35° till 55°
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(a) (b)

Fig. 4. Bending samples formed by the 10 mm die radius (a) Failed samples and (b) succeeded samples heated in ofen up to 240°C.

4. Experimental results

4.1. Characterization of the laminate parameters by hot V-bending

It was found that the most affecting parameters were the tool radius and the heating temperature during the V-bending process.
The lower the tool radius the higher was the failure of the samples. The samples failures were presented by fracture, buckling,
delamination and wrinkling as shown in Fig. 4 (a). The succeeded samples were operated by the 10 mm radius tool. On the other
hand, the influence of heating temperature on both tool and BFRP laminate samples was investigated.
Only the die was heated during V-bending experiments. The 300 °C heating temperature was causing the basalt fiber and PA 6
matrix to flow out of the laminate structure. Whereas, the samples formed below the 260 °C were suffered from wrinkling and
delamination leading to failure. As a result, it has become apparent that the optimum heating temperatures were 260 °C and 80 °C
for oven and bending die respectively as illustrated in Fig. 4 (b).

4.2. Hot SPIF of BFRP Laminate results

The same heating temperature conducted from the V-bending process was utilized to heat up the BFRP laminate during SPIF
process. The heating procedure during SPIF was to gradually increase the heating temperature because of rapid heating and forming
resulting in wrinkling, folding, internal cracks and large voids. Owing to the rapid heating which is casing a nonhomogeneous
distribution of the heat on all over the laminate thickness. Thus a gradual heating method was dependent to begin with 50 °C heating
temperature then increasing by 50 °C every 10 minutes till reaching the specified heating temperature. Finally, the PA 6 matrix
must be solidified after forming to hold up the basalt fibers. Therefore only air was pumped without heating to cool up the structure.
The hot SPIF method was performed for both laminate types to be formed into a conical shape of wall angle 35° and then adding
5° for the wall angle till material failed. Consequently, the final reached wall angle was 55° of both type I and type II laminates.
Many efforts and trials were performed to form a 56° or more conical wall angle but it was not possible to form it. Fig. 5 shows
that a half conical shape with 50° wall angle of type II laminate was formed by hot SPIF and divided into 3 zones. Obviously, the
laminated structures suffering from delamination and voids initiation by its production method or after reshaping [19]. Therefore,
each zone was cut and optically observed to analyses the voids and delamination after hot forming for each type of the samples.
The voids diameters and delamination distance were measured for each zone. The voids and delamination measurements were
calculated as a percentage from each zone area.
The percentage of voids and delamination were increased by forming with a larger profile wall angle as can be seen clearly in
Fig. 6 of zone I. The delamination percentage in type I laminate was greater than type II. Due to the fact, that the plastic properties
of aluminum sheet are much more different than the behavior of the BFRP during forming the greatest delamination was observed
between the two aluminum sheets and the BFRP. Meanwhile, the type II laminate has much less delamination and voids percentage
than type I laminate.
6 Amar Al-Obaidi / Procedia Manufacturing 00 (2018) 000–000
26 Amar AL-Obaidi et al. / Procedia Manufacturing 29 (2019) 21–27

Fig. 6. Half formed conical shape of type II laminate and devided into 3 enlarged zones.

The higher voids and delamination percentage was found in zone I. It is believed that at zone I the BFRP laminate experiencing
much more stresses than the rest two zones, because of that both tensile and stretching stresses take place in zone I by SPIF. In the
same time, as a confirmation of the stress theory, the percentage of voids in the lower part of type II laminate was much more than
those in the upper part of type II laminate because of the tensile stress. Furthermore, the thickness of zone I after forming was much
less than 18.5% and 14.25 % when compared with the original thickness of type II and type I BFRP laminate respectively.

Fig. 5. Voids and delamination percentage in zone I of 50° cone wall angle.
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5. Conclusions

The thermoplastic BFRP laminate was successfully formed by hot SPIF process. In this method two laminate types were
investigated: I of BFRP impeded between two aluminum sheets and type II with only one aluminum sheet inserted between two
layers of BFRP. These laminates were investigated to be formed into conical shapes. The BFRP laminate of type I was sandwiched
between two dummy metal sheets during hot SPIF. Furthermore, type II laminate was inserted between two Teflon layers and two
dummy metal sheets in hot SPIF. Therefore, the metallic sheets were used to protect the laminate from forming tool friction and
excessive heating effects. At the same time, the Teflon layers were used to improve the sliding of the BFRP during SPIF assisted
by hot air heating. Conical shapes in a variety of wall angles were formed. The wall angle of ≥ 50° is suffering from delamination
and voids initiation. As a result, SPIF assisted by hot air heating is a suitable method in the prototype manufacturing of parts for
prosthetics and orthotics which are generally implemented in medical applications. Moreover, conventional forming methods like
deep drawing only a fixed shape of parts can be produced. Whereas, SPIF is more flexible and gives the opportunity to form an
unlimited shapes and thus save costs for expensive rigid tools. Due to the long cycle time for incremental forming, this is only
worthwhile for small quantities. Moreover, the investigated process requires further development and investigations to solve the
related defects and reduce the delamination and voids initiation.

Acknowledgments

The authors would like to thank the Institute of Machine Tools and Production Processes (IWP) (Institut für Werkzeugmaschinen
und Produktionsprozesse) and Cetex Institut für Textil- und Verarbeitungsmaschinen gemeinnützige GmbH for their technical
support. The authors would like also to thank the AiF and ZIM (Zentrales Innovationsprogramm Mittelstand) for the support of
project number (2310581).

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