Research into sheet metal forming, friction, sustainable manufacturing and design

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The objective of the proposed work is to conduct research into Single Point Incremental Forming (SPIF), Friction in Metal Forming, and Sustainable Manufacturing (Energy and Carbon Emissions). SPIF is a relatively new sheet metal forming process that can be used to make rapid prototypes for use in products. The process does not require a dedicated forming die and uses simple of-the-shelf technology. Although SPIF can be used to make rapid prototypes from steel and aluminum sheet, many issues still exist, including: using this process to make parts in larger quantities; forming more exotic materials such as Titanium and Magnesium; increasing the accuracy of the SPIF made parts; reducing tool wear. Recent research shows that electrically assisted forming (EAF) can be used to increase the formability of Titanium and Magnesium. The work proposed will examine how this can be done with SPIF. The SPIF process provides a method for testing metal forming lubricants and measuring coefficients of friction in metal forming. Hence, we propose to develop this as a method of finding coefficients of friction in sheet metal forming, thereby eliminating the need to purchase, dedicated equipment. Once validated, the friction characteristics of eco-friendly lubricants will be examined. The Global Warming Potential (GWP) of lubricants will also be determined. Sustainable Manufacturing and Design are important to society. This work will focus on the force and energy signatures for standard metal forming processes, measuring where needed, both in our lab and in industry, including the energy needed for ancillary equipment which consumes a large amount of energy. Different manufacturing configurations will be tested including, different SPIF configurations. With this knowledge Carbon Signatures will be developed for individual metal forming processes using the carbon emission signature developed in our lab. This work will be done in collaboration with international colleagues working in this area. The total HQP will include: two PhD's, eight MSc's and five BSc's.