The Nickel-Titanium (Ni-Ti, Nitinol) alloy demonstrates shape-memory (SMA) characteristics, enabling it to change shape when subjected to heat treatment, along with superelastic (SE) properties that enhance its flexibility and durability. In contrast to various other metals and alloys, Nitinol can undergo deformation ranging from 10 to 30 times more and still recover its initial shape. Normally, Nitinol contains a nickel percentage ranging between 50 and 51 atomic per cent (equivalent to 55 to 56 per cent weight per cent) [1]. Nitinols have found successful applications as biomaterials and in diverse engineering fields such as the creation of stents, guide wires, and orthodontic archwires [2]. Shape-memory alloys (SMAs) derived from these materials have been utilized as thermal actuators in the automotive industry for various functions, including engine control, fan clutches, radiator shutters, brake ventilation, fuel management, transmission control, climate control, and minimizing noise from rattling [3]. Nitinol is additionally employed in numerous roller and ball bearing uses owing to its exceptional resistance to corrosion and relatively high durability.
There is a wide array of applications for sheet metal, spanning from basic trays to intricate components in construction, automotive, aviation, boilers, kitchenware, office supplies, and various household and food-beverage appliances. Through the use of a die and punch, sheet metal gets shaped into the specific geometries required for these applications. Despite their natural ductility, sheet metals have limits in their production, with failures such as fracture and necking occurring beyond a certain point, known as the forming limit. The forming limit diagrams (FLDs) serve as a valuable tool for accessing the formability of sheet metals. Strains are measured at the points of component failures, and these measured strains are used to construct FLDs. The formability of sheet metal is influenced not only by friction but also by factors such as blank holding pressure, lubrication, strain pathways, and the severity of the forming process [4].
Conventional sheet metal forming relies on punch and die mechanisms but has its limitations, including reduced strain capacity, challenges related to friction between the metal and the die, difficulties in lubrication, and the need for highly intense shaping. Moreover, the cost associated with the die and punch is considerably high. As a result of issues like necking, wrinkling, fracture, and earing, the traditional press-forming methods for sheet metal encounter limitations. Besides, in small-scale manufacturing, traditional press forming methods tend to become costlier due to the need for dedicated punch and die sets, hydraulic presses, and specialized tool designers. Conventional farming also tends to reduce the formability of complex structures because of varying strain paths and excessive strains involved.
To address these challenges, incremental sheet formation presents a solution. In single-point, incremental forming (SPIF), a ball-ended forming tool follows specified pathways determined by the user. This gradual deformation process used in SPIF allows for the gradual shaping of the sheet, resulting in increased limits to strains and overcoming some of the limitations associated with conventional forming [5].
The production of micro components is gaining significant importance across various industries like medical engineering, optics, bioengineering, and engineering surfaces with specific qualities. To fabricate these diverse micro components, a range of techniques has been developed, including micro-EDM, the LIGA process, precision-micro cutting, nano-imprinting, and various beam processing methods. Even within different forming procedures like micro-deep drawing [6], micro extrusion [7], micro indentation for surface texture modification [8], micro punching [9], and micro-grooving in spinning [10], the focus has been on product miniaturization.
Factors like friction and grain size play crucial roles in product miniaturization within these processes [11, 12]. Among these techniques, the single point micro incremental forming (SPMIF) process stands out as particularly suitable for developing miniature products. It requires less tooling and ensures a good surface finish, making it an ideal choice for creating these small-scale components.
The adoption of SPMIF for developing microdevices and robots with thicknesses less than 1 mm was explored by Saotome and Okamoto et al. [13]. Y. H Kim et al. [14] conducted research focused on Al 1050 to evaluate its response to incremental sheet forming, examining the impact of process variables. Meier et al. [15] utilized a robot cell to incrementally deform aluminium material, achieving higher precision in their outcomes. Jackson et al. [16] identified that stretching and shear, both perpendicular and parallel to the tool direction respectively, were the primary causes of deformation in the incremental sheet forming (ISF).
Given the wide applications of micro-structured components, efforts have been made to scale down ISF to the micro level. Zhao and Zhu [17] demonstrated SPMIF using modified CNC machinery to deform multi-stage foils and analyzed formability during the process. Sekine and Obikawa [18], in their pursuit of developing miniature components, constructed a dedicated CNC machine for experimental SPMIF and studied the formability of different aluminium alloys. Further studies focused on specific materials and techniques: Sharma et al. [19] experimented with Ni-Ti sheets, examining parameter effects on formability during laser forming. Prasad et al. [20] delved into the microstructural, mechanical, and formability aspects of a newly developed Nitinol alloy containing Hf and Ta. Yoganjaneyulu et al. [21] investigated the influence of tool diameter and speeds on the fracture behaviour (void coalescence) of titanium grade 2 sheets, noting higher spindle speeds enhanced formability and larger tool diameters resulted in greater deformation and fracture strain. Vigneshwaran et al. [22] studied the relationship between strain triaxiality and void coalescence in aluminium alloys during cryorolling. Narayanasamy et al. [23–25] explored forming behaviour using sheets of various thicknesses, connecting properties like forming limit, fracture limit, wrinkling limit, void coalescence, and length-to-width (L/W) ratio with shear forces and material variables for a comprehensive understanding.
It appears that while there is a considerable focus within SPIF research on aluminium, copper and steel alloys, there's a noticeable lack of literature when it comes to SPIF applications involving Nitinol. Nitinol has extensive usage in various fields such as biomedical implants, automotive actuators, electrical devices, and aerospace applications. Additionally, there's an absence of direct literature specifically addressing SPIF and SPMIF techniques applied to Nitinol.
The current study aims to shed light on the mechanisms that dictate formability, fracture behaviour, and the overall formation process during SPMIF involving Nitinol. The research also delves into the influence of spindle speeds on formability during SPMIF. Furthermore, the investigation into fracture behaviour involves analyzing strain triaxiality and establishing correlations with void coalescence and intercrystalline separation for a comprehensive understanding of the material behaviour during the SPMIF process.