A review study on

Deformation Mechanism of
ISF of Metals and Polymers
PRESENTED BY: SAURABH THAKUR
UNDER THE GUIDANCE OF DR. PARNIKA SHRIVASTAVA

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 Layout of Presentation
Introduction
Literature
• Deformation studies in ISF of Metals
• Deformation studies in ISF of Polymers

Research Gaps and Scope of Future Work

Deformation Mechanics in Metals
Analytical Models (Metals)
• The Sine Law
• Membrane Analysis

Membrane Analysis Polymers

Conclusion & Future objectives
References

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 Introduction
•SPIF, although not a direct replacement of the traditional manufacturing process, has been established as a high
potential process for rapid manufacturing, low volume production and certain key applications
•SPIF has higher formability limits than other sheet metal forming processes including stamping, and is therefore
a desirable method of forming sheet metal components
•To take advantage of this high formability it is necessary to understand how is deformation achieved in ISF and
how to maximize the limits through manipulation of parameters
•With the advancement of biomedical field and advent on new biocompatible polymers, increasing the current
knowledge on deformation, formability and failure of such materials with the aim of identifying the feasibility of
applying them to the manufacturing of customized medical devices and prostheses is necessary
•Having a clear idea of deformation mechanics will help exploring the possibility of ISF of polymer-based
composite materials with application prospects

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 Introduction
•The deformation in SPIF has always been a subject of controversy
•Some researchers believe that the governing mechanics for the deformation is shearing and some are of the
opinion that it takes place due to stretching
•Research into the deformation mechanics has focused on two approaches: experimental measurement of
strains and displacements of the surfaces of sheets; and the use of the finite element (FE) method for prediction
of strains through the thickness
•The incremental forming processes have the same capability of enhancing formability above the conventional
limits in polymeric sheets that they had widely proved to have in metals
•However, the knowledge regarding deformation mechanics is limited and sometimes contradictory in both
metals and polymers

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 Literature
Deformation studies in ISF of Metals
• In the earlier development of the mechanics of ISF process was assumed to be similar to conventional spinning process i.e., shear
dominant deformation

• Based on this assumption Kim & Yang (2000) formulated a deformation mechanism and FEM was used to find the final thickness
strain. The initial rectangular meshes of each product were preserved well, even after initial sheet deformed into final shape. It was
reasonable to assume, as an engineering approximation, that all deformation occurred by only shear deformation

• Iseki (2001) proposed a plane strain deformation model and used FEM to calculate the deformation of a shell bulged incrementally
assuming that the sheet metal in contact with the tool stretches uniformly. Both calculations were found to be in reasonable
agreement validating the plane strain model.

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 Literature
•Shim & Park (2001) carried out an investigation of the unique pattern of the forming limit curve by imposing
various strain paths and major and minor strains were measured. It was found thar near equi-biaxial stretching
occurred at the corners and along a side near plane strain stretching occurred

•Filice et al. (2002), while measuring material formability taking into account a wide range of typical straining
conditions, obtained a forming limit curve quite different from a traditional one found ISF to be characterized by
a local stretching deformation mechanics

•Several forming strategies have also been proposed and compared with previously used linear bending
methods. Hirth et al. (2004) in hope to overcome the existing limitations to the process proposed one such
strategy but the deformation mode, again, was assumed to be very close to plane strain

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 Literature
•A detailed study of the process from its genesis to conceptualization to its recent practical utilization was done
by Jeswiet et al. (2005). The work provided a design and manufacturing guideline by dwelling into every aspect
of the process. Effect of increment step size and the draw angle accompanied with formability, force, plasticity
and springback analysis was studied. The formability mechanism, for previous and subsequent collaborated
studies for analyzing wall thickness variations or constructing forming limit diagrams, was assumed to be
primarily shear and a constant volume law i.e. sine law was favored to when determining the final thickness of
the material

•Emmens (2007) discussed the shear forming mechanism in ISF and also explored the possibility of stretching.
The shear deformation mechanism had its roots in conventional spinning processes and there was no direct
experimental evidence. Experimental evidence in this research showed that the behavior of a material under
conditions of a constantly changing strain path was extremely complex and the assumption that forming
processes was supposed to act under forming by shear is not true in its entirety

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 Literature
•Allwood et al. (2007) saw significant through thickness shear parallel to the tool path in their study. The
research did not support the idea that the deformation was primarily due to vertical shear as deduced by sine
law. Further research explored forming limits of ISF considering any proportional loading including six
components of symmetric stress tensors

•Silva et al. (2008) also stated the obvious confusion in deciding the governing deformation mechanism in ISF and
to help understand the fundamentals better proposed a theoretical model for SPIF based on membrane analysis
and on the experimental observation of the smear mark interference between the tool and the surface of the
sheet

•Further research by Silva et al. (2008) and Martins et al. (2008) to investigate the formability limits of SPIF
assumed stretching to be the principal mode of deformation

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 Literature
•Allwood & Shouler (2009) extended previous research by proposing new generalized FLD based on observation
of through thickness shear while the old FLDs were developed assuming that deformation occurs in plane stress

•Kathryn and Allwood (2009) experimentally examined the deformation mechanism of ISF in specially prepared
copper sheets in the form of truncated cones. The measurements showed that the deformation mechanism was
a combination of bending, stretching and shear for both SPIF and TPIF, the greatest strain component for both
ISF processes was shear in the tool direction, whilst perpendicular to the tool direction both stretching and
shear are of similar magnitudes

•Assuming that the deformation between intermediate shapes proceeds by displacements along the surface
normal of the current shape a new model for the kinematics of ISF process was proposed by Bambach (2010).
The new model yielded better thickness estimates than the sine law, especially in non-flat part areas where
strains parallel to the direction of tool motion are significant

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 Literature
•Major research interest includes developing a general analytical model for deformation which is capable of
predicting strain distribution for arbitrary geometries. For simplicity analysts have modelled deformation on the
basis of plane strain while equi-biaxial state has been modelled only by a few

•Cui et al. (2013) developed a mathematical model of deformation as an extension of the sine law for any part shape
assuming that the material only undergoes pure stretching. An open loop multi stage deformation pass model to
achieve a uniform thickness distribution has been developed only by considering deformation due to shear by Liu et
al. (2013)

•Several FEA models have also been developed after the advances in computational methods and speeds even
though it still remains a challenging task. Li et al. (2017) confirmed from the FE simulation that the deformation
modes in the ISF process are a combination of shearing, bending and stretching, although the quantitative
contributions in each direction are varied

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 Literature
•Ai et al. (2017) presented a new analytical model focusing on investigating the deformation stability and its
effect on the metal sheet fracture and obtained the critical strain of deformation instability also concluding that
bending plays a major role on ISF deformation stability

•Maqbool & Bambach ( 2017) tries to quantify the contribution of every type of deformation mechanism in the
SPIF process. This can be done by splitting the plastic energy dissipation into contribution made by membrane
stretching, bending and though thickness shear deformation. This revealed that dominant deformation mode
depends upon selected process variables like tool diameter, toll stepdown, blank thickness and friction

•Yazar et al. (2019) studied the deformation mechanism by observing changes in microstructure and lattice
rotation and found that deformation is majorly plane strain with a contribution of through thickness shear
whose magnitude strictly depends on tool diameter and vertical step size

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 Literature
Deformation studies in ISF of Polymers
•It has been widely acknowledged that stretching leading to membrane strain is the dominant
deformation mode in the ISF process
•For the deformation mode of plane strain stretching conditions, Silva et al. (2009) proposed a
theoretical framework of membrane analysis on the deformation mechanism of sheet metal
in rotational symmetric SPIF
•Silva et al. (2010) innovatively extended the membrane approach developed before to model
the cold plastic deformation of thermoplastic materials with the typical pressure-sensitive
yield surfaces

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 Literature
•Marques et al. (2012) stated that in SPIF of not only metallic but also thermoplastic materials, there are three
basic deformation modes including (a) plane strain stretching on flat surfaces, (b) plane strain stretching on
rotational symmetric surfaces and (c) equi-biaxial stretching at corners

•They extended the analytical framework for the condition of rotational symmetry to the corner of the formed
part to make both these two extreme and special deformation modes focused on SPIF of thermoplastic
materials. Following the analytical procedures used by Silva et al. they obtained the stress distribution under the
condition of equi-biaxial stretching. Based on previous study results and their derivation, the authors
summarized the stress and strain state in the small localized plastic zone of SPIF of thermoplastic and metallic
materials under both plane strain conditions and equibiaxial stretching conditions

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 Literature
•Sy et al. (2012) selected a modified viscoelasticity theory based on overstress and the simulation and
experimental results showed good agreement for the prediction of the thickness and the forming accuracy
•Apart from the membrane analysis, Bagudanch et al. (2013 and 2014) attempted to find a suitable material
constitutive model to describe the stress-versus-strain states of PVC sheet and further to be used in FE
simulation of ISF
•Yonan et al. (2013) developed a non-linear visco-plastic material model used in ISF of thermoplastics and
extended it to the FE simulation of PVC parts shaped by SPIF
•However, this material model has limited applicability only with small deformations, making it difficult to
analyze the plastic flow and the stress states for large strain. To solve this problem Yonan et al. (2014)
subsequently proposed an alternative and effective method, focusing on the characterization of plastic flow and
failure in SPIF of thermoplastic materials

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 Research Gaps and Scope of Future
Work
•The full profile of deformation through the thickness of the sheet has never been measured experimentally. This would
validate numerical models, which have sometimes provided contradictory results to experimental measurements
•Furthermore, the deformation mechanisms of SPIF and TPIF have never been clearly distinguished, and there is no
reason why they should necessarily be the same
•The physical mechanism behind the material behavior of thermoplastics, such as strain softening and strain hardening,
has not been fully understood particularly under the ISF deformation conditions
•In metals new popular deformation mechanism are being discussed, through thickness shear deformation and bending
under tension, they are taken into consideration while determining the governing mechanism of deformation in
polymers
•Little attention has been paid in numerical simulation for ISF of thermoplastic materials, which is an important research
aspect
•There is a need to construct the forming limit curve (FLC) at fracture for some important types of biocompatible
thermoplastics, e.g. polyetheretherketone (PEEK)

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 Deformation Mechanics in Metals
•Measurements and numerical simulations of SPIF have shown that for a conventional spiral tool path along
straight or gently curved sides, material does not move significantly in the direction parallel to the plane of the
undeformed sheet, but moves mainly normal to this plane
•Hence, strains on the surface of the sheet are zero or negligible parallel to the tool direction and positive
perpendicular to the tool direction, and these directions correspond to the minor and major directions of
surface strain respectively
•Early work in finding the governing mechanics found the strains to be uniaxial
•Later non-zero minor surface strains were achieved under certain conditions. The strain state at the start and
end points of the line was found to be biaxial, whilst the strain in the middle was assumed uniaxial
•The two extremes in the ongoing discussion in literature are pure stretching with bending at the edges and pure
vertical shear

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 Analytical Models (Metals)
•Major research interest includes developing a general analytical model for deformation which is capable of
predicting strain distribution for arbitrary geometries
•For simplicity analysts have modelled deformation on the basis of plane strain while equi-biaxial state has been
modelled only by a few
•The simplest model based on the assumption of plane strain and volume consistency is the sine law. A
mathematical model of deformation as an extension of the sine law for any part shape assuming that the
material only undergoes pure stretching has also been developed
•A new analytical model focusing on investigating the deformation stability and its effect on the metal sheet
fracture and obtained the critical strain of deformation instability also concluding that bending plays a major
role on ISF deformation stability has also been developed

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 Analytical Models (Metals): The Sine Law
• The sine-law is a geometrical consequence of plane strain deformation and volume constancy
• It was initially stated for shear spinning, but proved also to be valid in most cases of SPIF
• It relates initial thickness to with thickness after forming tf

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 Analytical Models (Metals): The Sine
Law
•The sine-law explains why high drawing angles approaching 90° can never be realized with one stage SPIF which
is normally close to plane strain for the majority of the part
•As ψ approaches 90° the strains goes towards infinity
•But the accuracy of the sine law for prediction of wall thickness in SPIF has been found to be variable across the
profile of a formed product

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 Analytical Models (Metals):Membrane Analysis
•Despite the major contributions made by researchers the mechanics of deformation remains little understood
•Silva et al. tried to answer the questions related to deformation based on membrane analysis of the small plastic
zone created by the single point tool during forming of rotational symmetric components

Fig. 1: Schematic representation of a cross section view of the rotational symmetric single point incremental forming
(SPIF) process

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 Analytical Models (Metals):Membrane
Analysis
•The metal is stretched by membrane forces, so that it conforms to the hemispherical shape of the tool, forming
a contact area between the tool and the part of the sheet placed immediately ahead of the moving tool
•The contact area is characterized as a small zone localized at the corner of the deforming sheet with a shape
resembling that of a radial slice
•The instantaneous small plastic zone typical of rotational symmetric SPIF can be approximated by a local shell
element CDEF as depicted in figure

Fig. 2: schematic representation of the shell element in perspective

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 Analytical Models (Metals):Membrane Analysis
•In SPIF the local shell element is subjected to
normal forces, shear forces, and bending moments.
•However, the membrane analysis of plastically
deforming shells neglects the bending moments
and, because of axial symmetry, assume the
circumferential, meridional, and thickness stresses
to be principal stresses
•Further simplifying assumptions are:
• material is assumed as rigid perfectly plastic; i.e. no
strain-hardening effects are taken into consideration
• material is assumed isotropic; i.e. no anisotropic
effects are taken into consideration

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 Analytical Models (Metals):Membrane
Analysis
•The model is built upon membrane analysis and is based on the examination of the likely mode of material
failure at the transition zone between the inclined wall and the corner radius of the sheet
•Cracks in SPIF are claimed to be opened by meridional tensile stresses and not by in plane shearing stresses

Fig. 3: Schematic illustration of the typical crack propagation path in

SPIF

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 Analytical Models (Metals):Membrane Analysis
•Table below presents the strains and stresses along the principal directions that are derived from the analytical
framework of SPIF

State of stress and strain in the small localized plastic zones and inclined
walls of SPIF

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 Membrane Analysis Polymers
The assumptions set up to simplify the model are:
•Bending moments were neglected and circumferential, meridional and thickness stresses are principal stresses;
•The material is rigid perfectly plastic and strain hardening effects are ignored
•The utilized yield criteria was the pressure-modified Tresca and von-Mises criteria
•No material anisotropic effects are taken into account
•The frictional stress at the contact surface between tool and sheet is just made of in-plane meridional and
circumferential components

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 Membrane Analysis Polymers

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 Membrane Analysis Polymers
•The mechanics of deformation associated with failure mode 1 is caused by stretching mechanisms due to
meridional tensile stresses. The morphology of the cracks and its propagation paths, along the circumferential
direction, are similar to those usually found in the SPIF of metals
•Failure mode 2 is caused by wrinkles that are twisted about the axis of revolution in the direction of rotation of
the forming tool and is triggered in the region of the inclined wall placed in the immediate vicinity of the corner
radius
•Failure mode 3 leads to a premature collapse of the SPIF parts and seems to be related with the redundant
straining that is produced as the forming tool progresses along the circumferential direction. Redundant
straining is due to simultaneous straining by shearing on the surface and by bending

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 Membrane Analysis Polymers

Fig. 4: Failure modes that are experimentally observed in the SPIF of polymers. a Failure mode 1. b Failure
mode 2. c Failure mode 3

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 Conclusion & Future objectives
•Polymeric materials can observe the relaxation and creep behavior, and recovery at zero stress at
room temperature which makes the deformation mechanism complex and numerical simulation
harder to develop.
•The process parameters in ISF of metals and polymers affected the deformability differently
•The sine law for volume consistency results in sometimes result in inhomogeneous thickness.
•Recent goals will be fixed on choosing a specific application in biomedical field e.g. clavicle
implants, skull prothesis, cranial implants, denture based implants, knee implants or any other
biomedical application.
•Secondly based on thermo-mechanical and deformation FE simulation a choice of material has to
be made between metals and polymers or polymer composites for the choice of material
•Experimentation to justify the numerical model for deformation and failure mechanisms will be
studied and FLDs will be developed.

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 Thank You

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