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When materials are subjected to forces that surpass their yield strength, they undergo a process known as plastic deformation. This results in a permanent alteration or strain in their structure. This concept can be specifically applied to circular shafts, where the deformation leads to a change in its shape. The precise evaluation of this plastic deformation requires understanding the stress distribution within the circular shaft, which is achieved by calculating the maximum shearing stress in...
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Experimental Procedure for Warm Spinning of Cast Aluminum Components
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Novel Acetal Rotating Tool Improving Surface Quality in Incremental Sheet Forming.

Hongsong Song1, Kai Han1,2, Peng Xu3

  • 1AECC Beijing Institute of Aeronautical Materials, Beijing 100095, China.

Materials (Basel, Switzerland)
|February 27, 2026
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Summary

A novel acetal wheel-type rotating tool significantly enhances surface quality in incremental sheet forming (ISF) by 32-40%. This innovative tool reduces contact stress and eliminates tool wear, offering a practical solution for industrial applications.

Keywords:
acetal rotating toolforming toolincremental sheet formingsurface quality

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Area of Science:

  • Materials Science and Engineering
  • Manufacturing Processes

Background:

  • Surface quality is a major limitation for the widespread adoption of incremental sheet forming (ISF).
  • Existing metal ball tools in ISF often lead to suboptimal surface finish and tool wear.

Purpose of the Study:

  • To develop and evaluate a novel acetal wheel-type rotating tool for ISF.
  • To investigate the impact of tool structure and material on surface quality in ISF.
  • To compare the performance of the novel tool against conventional metal ball tools.

Main Methods:

  • Experimental analysis of surface quality with the new tool.
  • Numerical simulations to understand sheet-tool contact and stress distribution.
  • Comparative studies using acetal wheel-type tools versus traditional metal ball tools.

Main Results:

  • The acetal wheel-type tool improved surface quality by 32-40% compared to metal ball tools.
  • Enhanced sheet-tool contact area with the acetal tool suppressed surface waviness.
  • Contact stress was reduced by over 37.5%, and surface quality improved by 21.1% relative to metal ball tools.
  • The acetal rotating wheel achieved a 32.0% surface quality enhancement with zero tool wear.

Conclusions:

  • The novel acetal wheel-type rotating tool offers a significant improvement in surface quality for ISF.
  • This tooling solution effectively mitigates surface waviness and reduces contact stress.
  • The acetal tool's durability and performance make it highly applicable for industrial ISF processes.