Browsing by Author "Rahul Ramlal Gurpude"

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Formability improvement in die less forming process of Ti Gr. 2 perforated sheet: experimental method and finite element analysis
(Springer-Verlag Italia s.r.l., 2025) Rahul Ramlal Gurpude; Amrut Shrikant Mulay; Pawan R. Sharma
The SPIF technique stands out as a versatile method aimed at forming sheet metal components, especially in circumstances where production volumes are limited. A crucial aspect in SPIF revolves around maintaining meticulous control over process variables to ensure that fabricated components stick to required dimensional specific production. This study focuses on influence of variable process factors on formability of perforated Ti Gr.2. The investigation primarily investigates into geometrical factors such as tool and hole diameters, recognizing their key role in defining formability of perforated sheet. The numerical simulations is conducted through ABAQUS® software serve as backbone of this investigation. As temperature levels rise, the materials ductility proportionally increases, rendering the sheet more ductile and easier for forming. The outcomes derived from the experiments highlight the deep impact of hole diameter on material formability. Furthermore, study investigates into assessment of Von-Mises stresses, plastic equivalent strain (PEEQ), and thickness distribution across varied input process parameters. Remarkably, the results expose a direct correlation between hole size and fracture depth, exposing a critical aspect of material behaviour under SPIF conditions. Moreover, the analysis extends to examining variations in microstructure and hardness between the as received material and optimal formed samples. © The Author(s), under exclusive licence to Springer-Verlag France SAS, part of Springer Nature 2024.
Selection of tool-hole size and development of cranial implants for Ti Gr.2 perforated sheet during the flexible die-less forming process
(Springer Science and Business Media Deutschland GmbH, 2025) Rahul Ramlal Gurpude; Amrut Shrikant Mulay; Pawan R. Sharma
Single-point incremental forming is a versatile and flexible technology for manufacturing sheet metal components in small series. However, SPIF in the biomedical field can be difficult because there are many challenges. One of the main issues is controlling the settings of the process and making sure the components meet the required size standards for production. The primary goal of this study is to determine the impact of various process parameters on the formability of perforated titanium grade 2. The geometrical parameters, such as tool and hole diameters, were initially investigated for the formability of sheet material. Later, SPIF parameters, such as toolpath, feed, and step depth, were varied at three levels, and the part responses were recorded in terms of roughness, maximum temperature, and angle of failure. The results reveal that the hole diameter, tool diameter, and surface roughness, respectively, are significant factors for formability and the highest temperature attained during the process. It is found that surface roughness begins to decrease as the tool diameter increases for the perforated sheet. The hole diameter of 10 mm and tool diameter of 4.5 mm is found to be used optimal combination. The cranial implants were prepared with optimal tool-hole diameters combinations, and all sound parts were evaluated for roughness, thickness deviation, and accuracy. The cranial implant, formed with follow-periphery, feed rate of 300 mm/min, and a step depth of 0.2 mm, results in sound part with improved forming accuracy and a reduction in surface roughness. The variation in microstructure and hardness for base and optimally formed sample were also investigated. © The Author(s), under exclusive licence to The Brazilian Society of Mechanical Sciences and Engineering 2024.