Extrusion is a process that used to create objects of a fixed cross-sectional profile. A material is pushed through a die of the desired cross-section. The main advantage of this process with respect to other manufacturing processes is its ability to create very complex cross-sections, while the limitation of extrusion process is used to produced just a symmetric profile so this paper proposed an adopted algorithm that used to design and implementation the Asymmetric extrusion die that used to prevent the twisting that caused in metal when used to produce the Asymmetric product, and in other wise reduce the total extrusion power and die pressure distribution on metal during extrusion process. This adopted design was implemented in this work using Teflon material in both symmetric and asymmetric profile using CNC milling machine to demonstration the success of this algorithm.

Multipoint forming process is an engineering concept which means that the working surface of the punch and die is produced as hemispherical ends of individual active elements (called pins), where each pin can be independently, vertically displaced using a geometrically reconfigurable die. Several different products can be made without changing tools saved precious production time. Also, the manufacturing of very expensive rigid dies is reduced, and a lot of expenses are saved. But the most important aspects of using such types of equipment are the flexibility of the tooling. This paper presents an experimental investigation of the effect of three main parameters which are blank holder, rubber thickness and forming speed that affect the surface integrity for brass (Cu Zn 65-35) with 0.71 mm thickness. This paper focuses on the development of prediction models for estimation of the product quality. Using Analysis of Variance (ANOVA), surface roughness has been modeled. In the development of this predictive model, blank holder, rubber thickness and forming speed have been considered as model parameters. The mean surface roughness (Ra) is used as response parameter to predict the surface roughness of multipoint forming parts. The data required has been generated, compared and evaluated to the proposed models obtained from experiments. Taguchi algorithm was used to predict the forming parameters (blank holder, rubber thickness and forming speed) on product roughness in forming process of Brass (Cu Zn 65-35) based on orthogonal array of L9 and finally ANOVA was used to find the optimum parameters that have effect on the product quality.

Multi-point forming (MPF) is an advanced flexible manufacture technology, and the technology results from the idea that the whole die is separated into small punches that can be adjusted height. This idea is applied to the traditional rigid blank-holder, so flexible blank-holder (FBH) idea can be obtained. In this work, the performance of a multi-point die is investigated with pins in square matrix and suitable blank holder. Each pin in the punch holder can be a significant moved according to the die high and at different load that applied with spring with respect to spring stiffness. The results shows the reduction in setting time with respect to traditional single point incremental forming process that lead to (90%). and also show during the forming process, the deformation of the interpolator can induce a shape error in the formed work-piece and the blank holder can reduce/eliminate dimples that sometimes arise in the work-piece. The minimum force applied using multi-point die is 28.556KN, while the load when complete the forming process is 30.8KN that caused displacement of die to 32.8mm.

Understanding sheet metal forming presses are important to reduce manufacturing costs. Thus, the best method of finding the optimum values of processing is by studying the effect of forming parameters on the behavior of formability, friction, and die radius. In this work, the deep drawing process of a low-carbon steel cup was studied and the significance of two important process parameters are investigated which are the friction coefficient and the radius of the die. The finite element method program, ANSYS, is used to study the effect of these parameters on forming load in the deep drawing process. The three ​​levels of friction coefficient are considered which are 0.08, 0.00, and 0.15, and three die shoulder radius of 4, 6, and 8 mm. The results show that the predicted behavior of the punch load coincided well with both experimental and practical behaviors and the confidence is exceeding 94%. The wrinkling defect is happening when using a high die radius, Rd=8mm although the punch load is low due to the increase in the surface area on the edge of the die.

Multipoint forming is an engineering concept which means that the working surface of the dieand/or punch is made up of hemispherical ends of individual active elements (called pins), whereeach pin can be independently, vertically displaced using a geometrically reconfigurable die,precious production time is saved because several different products can be made withoutchanging tools. The aim of this work is to present the effect of many parameters (blank Holdertypes, rubber thickness and forming speed) on the reduction of thickness for brass with 0.71 mmthickness. This research is concentrate on the development of predictive models to estimate theminimum deviation in thickness using analysis of variance (ANOVA), minimum thicknessdeviation has been modeled. In the development of this predictive model, blank holder, rubberthickness and forming speed have been considered as model parameters. Arithmetic theminimum thickness deviation used as response parameter to assess the thickness reduction ofMultipoint forming parts. The data required has been generated, compared and evaluated to theproposed models that obtained from experiments. Taguchi algorithm is used to predict theeffect of forming parameters on thickness reduction in forming process of Brass (65-35) basedon orthogonal array of L9. The analysis of variance was used to find the best factors that effecton the thickness deviation, The result of this research is the contribution of blank holder types,rubber thickness and forming speed with respect to minimum thickness deviation is (69.195,18.1 and 12.733) % respectively.