Multi stages toolpath optimisation of single point incremental forming process

Journal article


Hassanin, H., Yan, Z, El-Sayed, M., Eldessouky, H., Djuansjah, J., Alsaleh, N., Essa, K. and Ahmadein, M. 2021. Multi stages toolpath optimisation of single point incremental forming process. Materials.
AuthorsHassanin, H., Yan, Z, El-Sayed, M., Eldessouky, H., Djuansjah, J., Alsaleh, N., Essa, K. and Ahmadein, M.
Abstract

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. 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 have 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 had 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; toolpath; Optimisation
Year2021
JournalMaterials
PublisherMDPI
ISSN1996-1944
Publication process dates
Accepted04 Nov 2021
Deposited08 Nov 2021
Accepted author manuscript
License
File Access Level
Open
Output statusIn press
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