This work presents a comprehensive investigation of an experimental study conducted on ultra-high molecular weight polyethylene (UHMWPE) sheets using single point incremental forming (SPIF). The analysis is performed within a previously established research framework to evaluate formability and failure characteristics, including necking and fracture, in both conventional Nakajima tests and incremental sheet forming specimens. The experimental design of the SPIF tests incorporates process parameters such as spindle speed and step down to assess their impact on the formability of the material and the corresponding failure modes. The results indicate that a higher step down value has a positive effect on formability in the SPIF context. The study has identified the tool trajectory in SPIF as the primary influencing factor in the twisting failure mode. Implementing a bidirectional tool trajectory effectively reduced instances of twisting. Additionally, this work explores a medical case study that examines the manufacturing of a polyethylene liner device for a total hip replacement. This investigation critically analyses the manufacturing of plastic liner using SPIF, focusing on its formability and the elastic recovery exhibited by the material.
Keywords: SPIF; UHMWPE; failure; formability; springback; twisting.