Multipoint forming using mesh-type elastic cushion: modelling and experimentation

Tolipov, Abror; Elghawail, Ali; Abosaf, Mohamed; Pham, Duc Truong; Hassanin, Hany; Essa, Khamis

doi:10.1007/s00170-019-03635-z

Cited by 13 publications

(9 citation statements)

References 20 publications

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“…The design of experiments is a statistical approach for designing and optimising processes with multiple input parameters, and it has been used extensively in sheet metal forming as well [34,35]. The response surface method was used to statistically investigate the effect of the process parameters using the two forming stages' spiral tool paths and to find the optimised parameters, as shown in Figure 4.…”

Section: The Response Surface Methods (Rsm)mentioning

confidence: 99%

Multistage Tool Path Optimisation of Single-Point Incremental Forming Process

et al. 2021

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Single-point incremental forming (SPIF) is a flexible technology that can form a wide range of sheet metal products without the need for using punch and die sets. As a relatively cheap and die-less process, this technology is preferable for small and medium customised production. However, the SPIF technology has drawbacks, such as the geometrical inaccuracy and the thickness uniformity of the shaped part. This research aims to optimise the formed part geometric accuracy and reduce the processing time of a two-stage forming strategy of SPIF. Finite element analysis (FEA) was initially used and validated using experimental literature data. Furthermore, the design of experiments (DoE) statistical approach was used to optimise the proposed two-stage SPIF technique. The mass scaling technique was applied during the finite element analysis to minimise the computational time. The results showed that the step size during forming stage two significantly affected the geometrical accuracy of the part, whereas the forming depth during stage one was insignificant to the part quality. It was also revealed that the geometrical improvement had taken place along the base and the wall regions. However, the areas near the clamp system showed minor improvements. The optimised two-stage strategy successfully decreased both the geometrical inaccuracy and processing time. After optimisation, the average values of the geometrical deviation and forming time were reduced by 25% and 55.56%, respectively.

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Section: The Response Surface Methods (Rsm)mentioning

confidence: 99%

Multistage Tool Path Optimisation of Single-Point Incremental Forming Process

et al. 2021

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“…A general contact algorithm was used to define interfacial contact. A friction coefficient of 0.1 was assumed between all bodies to model tangential behaviour, and this was achieved using penalty formulation [ 36 , 37 , 38 ].…”

Section: Experimental and Methodsmentioning

confidence: 99%

“…The pin matrices, namely the punch and die, were modelled as rigid bodies and were meshed using R3D4 elements. In order to validate the model against previous work from our research group, the workpiece and cushion were defined as deformable and were meshed using C3D8R elements [ 34 , 36 , 39 ]. Also, shell elements, S4R, were used to mesh the workpiece as their computational cost is small, and the thickness distribution could be gauged more easily.…”

Section: Experimental and Methodsmentioning

confidence: 99%

Reconfigurable Multipoint Forming Using Waffle-Type Elastic Cushion and Variable Loading Profile

et al. 2020

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There is an increasing demand for flexible, relatively inexpensive manufacturing techniques that can accommodate frequent changes to part design and production technologies, especially when limited batch sizes are required. Reconfigurable multi-point forming (MPF) is an advanced manufacturing technique which uses a reconfigurable die consisting of a set of moveable pins to shape sheet metal parts easily. This study investigates the use of a novel variable thickness waffle-type elastic cushion and a variable punch-loading profile to either eliminate or minimise defects associated with MPF, namely wrinkling, thickness variation, shape deviation, and dimpling. Finite element modelling (FEM), analysis of variance (ANOVA), and the response surface methodology (RSM) were used to investigate the effect of process parameters pertaining to the cushion dimensions and type of loading profile on the aforementioned defects. The results of this study indicate that the most significant process parameters were maximum cushion thickness, cushion cut-out base radius, and cushion cut-out profile radius. The type of loading profile was found to be insignificant in all responses, but further investigation is required as the rate, and the thermal effects were not considered in the material modelling. Optimal process parameters were found to be a maximum cushion thickness of 3.01 mm, cushion cut-out base radius of 2.37 mm, cushion cut-out profile radius of 10 mm, and a “linear” loading profile. This yielded 0.50 mm, 0.00515 mm, 0.425 mm for peak shape deviation, thickness variation, and wrinkling, respectively.

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“…Selective laser melting (SLM) and electron beam melting (EBM) have the ability to melt metal alloy in full density and adequate mechanical properties [103]. Meanwhile, selective-heat-sintering (SHS) and selective laser sintering (SLS) can only increase the temperature of the processed powder below the melting point [104][105][106][107][108] (see Fig. 11).…”

Section: Powder Bed Fusionmentioning

confidence: 99%

Micro-fabrication of ceramics: Additive manufacturing and conventional technologies

et al. 2021

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Ceramic materials are increasingly used in micro-electro-mechanical systems (MEMS) as they offer many advantages such as high-temperature resistance, high wear resistance, low density, and favourable mechanical and chemical properties at elevated temperature. However, with the emerging of additive manufacturing, the use of ceramics for functional and structural MEMS raises new opportunities and challenges. This paper provides an extensive review of the manufacturing processes used for ceramic-based MEMS, including additive and conventional manufacturing technologies. The review covers the micro-fabrication techniques of ceramics with the focus on their operating principles, main features, and processed materials. Challenges that need to be addressed in applying additive technologies in MEMS include ceramic printing on wafers, post-processing at the micro-level, resolution, and quality control. The paper also sheds light on the new possibilities of ceramic additive micro-fabrication and their potential applications, which indicates a promising future.

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Multipoint forming using mesh-type elastic cushion: modelling and experimentation

Cited by 13 publications

References 20 publications

Multistage Tool Path Optimisation of Single-Point Incremental Forming Process

Multistage Tool Path Optimisation of Single-Point Incremental Forming Process

Reconfigurable Multipoint Forming Using Waffle-Type Elastic Cushion and Variable Loading Profile

Micro-fabrication of ceramics: Additive manufacturing and conventional technologies

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