Heat-assisted friction stir incremental sheet forming of thermoplastics

Incremental sheet forming (ISF) has been attracting increasing interests for customised manufacture of thermoplastics, but the application in high-performance and hard-to-form thermoplastics is still a challenge. This paper develops a new heat-assisted friction stir incremental sheet forming (HAFS-ISF) process to form polyether ether ketone (PEEK) and polymethyl methacrylate (PMMA, acrylic). Flexible heating tapes and tool rotational friction heat the thermoplastic sheet on both bottom and top surfaces, which maintain the sheet material at high temperature and reduce the through-thickness temperature gradient. Results are given for the effect of key parameters on forming temperature, force, accuracy and thickness distribution. Spindle speed has the most significant effect on all the studied aspects, followed by the pre-heating temperature, while feed rate and step size have less effect. With lower spindle speed of 100 rpm, the through-thickness temperature gradient is improved. Compared with PEEK parts, more uniform forming temperature and smaller forming force can be observed for PMMA parts. But the material brittleness causes worse formability, and the severer twist and stretching effect affect the forming accuracy of PMMA parts. Forming accuracy, fracture and twist are discussed by developing analytical models. The model for forming accuracy considers the initial bending effect and springback. The fracture is discussed by modelling the stress triaxiality and equivalent strain distribution under contact. While the model for twist considers effect of the applied torque on shear strain energy and continuous accumulation of twist along the tool path. By comparing analytical models and testing observations, the effectiveness of the models is confirmed to understand the underlaying mechanisms and to address a few challenges.