Sustainability assessment of incremental sheet forming: a review

Although incremental sheet forming (ISF) is featured with greater flexibility, lower cost, and shorter leading time, there is less comprehensive sustainability assessment for ISF. In order to summarize the research progress on the sustainability evaluation of ISF and further explore its potential application scenario specifically, the research with respect to energy consumption and environmental impact of ISF are reviewed in this paper. First, the characteristics and research status of ISF including geometry accuracy improvement, forming force prediction, and heating-aided ISF are introduced. Then, study on the influence of processing parameters, equipment, and consumables on energy consumption (both deformation energy and machine tool energy) and forming efficiency are comprehensively reviewed. Current research indicates that neither deformation energy consumption nor electric energy consumption of ISF is lower than stamping process since ISF has long motion trajectory and forming time. In addition, the current methods (such as Life Cycle Assess method) to assess the environmental impact of ISF are discussed. Additionally, the environmental impact of ISF mainly reflects on sheet material, energy consumption, and lubrication oil. Moreover, the comparison of the ISF process and the other processes with regard to sustainability is analyzed, which indicates that ISF has obvious advantage and broad prospects when the cost of molds is considered and the batch size is generally less than 1000. The study provides valuable guidance on the further improvement of ISF towards more efficiency and green manufacturing process.