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

Moheen, Mohammed; Abdel-Wahab, Adel A.; Hassanin, Hany; Essa, Khamis

doi:10.3390/ma13204506

Cited by 4 publications

(3 citation statements)

References 47 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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“…It was presented that the elastic pad thickness, pad cut-out base radius, and pad cut-out profile radius were the most important parameters. Optimum parameters were obtained for the pad thickness, pad cut-out base radius, and pad cut-out profile radius as 3.01, 2.37, and 10 mm, respectively [14]. Tolipov et al studied holetype rubber punches replacing the upper die for multi-point forming to reduce the pin arrangement time.…”

Section: Introductionmentioning

confidence: 99%

Experimental and Numerical Investigation on Effects of Pin Diameter on Multi-Point Forming

2023

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Multi-point forming (MPF) is an advanced and flexible method to form sheet metal workpieces. Although there are studies investigating different aspects of this method, the studies on the effects of pin diameter on sheet and pin contact on MPF are insufficient. In this study, pins with diameters of 10, 12, and 14 mm were used to investigate the damage factor, effective stress distribution, and required forming loads of three forms of aluminum 1100 parts in finite element simulations. In addition, experimental works were conducted for the 12 mm pin and the forming loads and the thinning on the contact points of pin and formed sheet metal parts were compared with the simulations. The 14 mm pin forming provided the highest effective stress distributions and the damage factors of 0.448, 0.770, and 0.329 were obtained for form1, form2, and form3, respectively. The percentage errors between experimental works and simulations using 12 mm pin forming were calculated as 7.4, 5.1, and 2.4% for all forms 1 to 3. In conclusion, pin diameter was shown to have significant effects on the MPF process. Larger diameter pins resulted in higher loads and tearing of sheet metal.

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“…Using the discrete cushion, the direct contact of the sheet metal with pin head is avoided; however, the die surface is discontinuous, and it affects the dimple height. Some attempts 25–28 proposed the use of different cushion types (composite, 26 mesh 27 , and waffle 28 ) in multi-point stamping to reduce the height of wrinkles.…”

Section: Introductionmentioning

confidence: 99%

Component specific elastic cushion design to enhance the accuracy with the usage of reconfigurable tools in stretch forming

Shivaprasad

Praveen

Reddy

2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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Multi-point stretch forming (MPSF) is a flexible manufacturing technology that uses reconfigurable tools to produce a variety of three-dimensional sheet metal components. An elastic cushion is placed between the surfaces of reconfigurable tool and the sheet metal to reduce the possibility of dimple formation. It is well known that elastic cushion deformation behavior significantly affects the accuracy and surface quality of components. In the present work, a component-specific elastic cushion is designed to achieve better conformability between the pin heads and cushion (by scooping out the material from the flat cushion selectively). An analytical model is developed to determine the volume of material to be scooped out and its location based on pin head and component geometries. To demonstrate the effectiveness of the developed methodology, finite element analysis (FEA) is performed to form double curvature (spherical) component with a cushion of constant thickness and a component-specific cushion with different pin matrix sizes. Results indicate that the deformation is more uniform with significant improvement in shape accuracy of the component formed with a component-specific cushion.

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

Cited by 4 publications

References 47 publications

Multistage Tool Path Optimisation of Single-Point Incremental Forming Process

Multistage Tool Path Optimisation of Single-Point Incremental Forming Process

Experimental and Numerical Investigation on Effects of Pin Diameter on Multi-Point Forming

Component specific elastic cushion design to enhance the accuracy with the usage of reconfigurable tools in stretch forming

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