Multistage Tool Path Optimisation of Single-Point Incremental Forming Process

Journal article

Yan, Zhou, Hassanin, H., El-Sayed, M., Eldessouky, Hossam Mohamed, Djuansjah, Joy Rizki Pangestu, A. Alsaleh, N., Essa, K. and Ahmadein, M. 2021. Multistage Tool Path Optimisation of Single-Point Incremental Forming Process. Materials (Basel, Switzerland). 14 (22), p. e6794. https://doi.org/10.3390/ma14226794
AuthorsYan, Zhou, Hassanin, H., El-Sayed, M., Eldessouky, Hossam Mohamed, Djuansjah, Joy Rizki Pangestu, A. Alsaleh, N., Essa, K. and Ahmadein, M.
AbstractSingle-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.
KeywordsSPIF; sheet metal; forming; incremental; FEA; tool path; optimisation
Year2021
JournalMaterials (Basel, Switzerland)
Journal citation14 (22), p. e6794
PublisherMDPI
ISSN1996-1944
Digital Object Identifier (DOI)https://doi.org/10.3390/ma14226794
Official URLhttps://www.ncbi.nlm.nih.gov/pmc/articles/PMC8620775/
FunderScientific Research at Imam Mohammad Ibn Saud Islamic University
Publication dates
Online11 Nov 2021
Publication process dates
Deposited08 Nov 2021
Accepted04 Nov 2021
Accepted author manuscript
File Access Level
Open
Output statusPublished
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