Optimisation of a novel hot air contactless single incremental point forming of polymers

Journal article

Almadani, M., Guner, A., Hassanin, H. and Essa, K. 2024. Optimisation of a novel hot air contactless single incremental point forming of polymers. Journal of Manufacturing Processes. 117, pp. 302-314. https://doi.org/10.1016/j.jmapro.2024.02.042
AuthorsAlmadani, M., Guner, A., Hassanin, H. and Essa, K.
Abstract

This study presents a new contactless sheet forming method that utilises hot air as a forming tool to address tool wear challenges in single-point incremental forming. Experiments were conducted on a 3-axis CNC machine equipped with a hot air nozzle on a polycarbonate sheet. A design of experiment (DOE) approach was employed, evaluating five control factors: air pressure, air temperature, feed rate, tool offset, and step down. The evaluation criteria for the formed sheets are profile variation, thickness variation, and surface roughness. The results indicate that air temperature and feed rate have the most significant influence on the deformation process. Additionally, air pressure and feed rate substantially impact both thickness variation and surface roughness of the formed material. To optimise the process parameters for high-quality forming, a prediction model is developed. The optimised process shows good agreement with the predicted model regarding profile and thickness variations. However, it does not align with surface roughness due to the stepwise nature and inherent waviness of the contactless forming technique. This study offers a promising approach for developing innovative contactless forming techniques using hot pressurised air as a forming tool. The proposed technique has the potential to significantly reduce tool wear and lubrication requirements.

KeywordsSheet forming ; Response surface methodology; Contactless incremental forming; Formability; Design of experiment
Year2024
JournalJournal of Manufacturing Processes
Journal citation117, pp. 302-314
PublisherElsevier
ISSN1526-6125
Digital Object Identifier (DOI)https://doi.org/10.1016/j.jmapro.2024.02.042
Official URLhttps://doi.org/10.1016/j.jmapro.2024.02.042
Publication dates
Print14 Mar 2024
Publication process dates
Accepted19 Feb 2024
Deposited28 Mar 2024
Publisher's version
File Access Level
Open
Output statusPublished
References

1. Radu, C., Effects of process parameters on the quality of parts processed by single point incremental forming. Int. J. Mod. Manuf. Technol, 2011. 3(2): p. 91-96.
2. Petek, A., K. Kuzman, and J. Kopač, Deformations and forces analysis of single point incremental sheet metal forming. Archives of Materials science and Engineering, 2009. 35(3): p. 107-116.
3. Abaas, T.F. and A.S. Bedan, The Effect of Tool Path Strategy on Mechanical Properties of Brass (65-35) in Single Point Incremental Sheet Metal Forming (SPIF). Journal of Engineering, 2013. 19(5).
4. Kim, Y. and J. Park, Effect of process parameters on formability in incremental forming of sheet metal. Journal of materials processing technology, 2002. 130: p. 42-46.
5. Azevedo, N.G., et al., Lubrication aspects during single point incremental forming for steel and aluminum materials. International Journal of precision engineering and manufacturing, 2015. 16(3): p. 589-595.
6. Durante, M., A. Formisano, and F. Lambiase, Incremental forming of polycarbonate sheets. Journal of Materials Processing Technology, 2018. 253: p. 57-63.
7. Rosa-Sainz, A., et al., Experimental failure analysis in polycarbonate sheet deformed by spif. Journal of Manufacturing Processes, 2021. 64: p. 1153-1168.
8. Martins, P.A.F., et al., Single point incremental forming of polymers. CIRP Annals, 2009. 58(1): p. 229-232.
9. Le, V., A. Ghiotti, and G. Lucchetta, Preliminary studies on single point incremental forming for thermoplastic materials. International Journal of Material Forming, 2008. 1(1): p. 1179-1182.
10. Essa, K. and P. Hartley, Optimization of conventional spinning process parameters by means of numerical simulation and statistical analysis. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2010. 224(11): p. 1691-1705.
11. Majagi, S.D. and G. Chandramohan. Optimization of incremental sheet metal forming parameters by design of experiments. in Applied Mechanics and Materials. 2014. Trans Tech Publ.
12. Le, V.S., A. Ghiotti, and G. Lucchetta, Preliminary Studies on Single Point Incremental Forming for Thermoplastic Materials. International Journal of Material Forming, 2008. 1(1): p. 1179-1182.
13. Jurisevic, B., K. Kuzman, and M. Junkar, Water jetting technology: an alternative in incremental sheet metal forming. The International Journal of Advanced Manufacturing Technology, 2006. 31(1-2): p. 18-23.
14. Jurisevic, B., et al. Incremental sheet metal forming process with a water jet and rigid tool. in Proc 17th International Conference on Water Jetting. 2004.
15. Yang, C., S. Sheu, and K. Yu, Optimal machining parameters in the cutting process of glass fibre using the reliability analysis based on the Taguchi method. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2008. 222(9): p. 1075-1082.
16. Bacchewar, P., S. Singhal, and P. Pandey, Statistical modelling and optimization of surface roughness in the selective laser sintering process. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2007. 221(1): p. 35-52.
17. Hussain, G., L. Gao, and N. Hayat, Empirical modelling of the influence of operating parameters on the spifability of a titanium sheet using response surface methodology. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2009. 223(1): p. 73-81.
18. Ham, M. and J. Jeswiet, Forming limit curves in single point incremental forming. CIRP annals, 2007. 56(1): p. 277-280.
19. Filice, L., G. Ambrogio, and F. Micari, On-line control of single point incremental forming operations through punch force monitoring. CIRP annals, 2006. 55(1): p. 245-248.
20. Ham, M. and J. Jeswiet, Single point incremental forming and the forming criteria for AA3003. CIRP annals, 2006. 55(1): p. 241-244.
21. Ambrogio, G., et al., An analytical model for improving precision in single point incremental forming. Journal of Materials Processing Technology, 2007. 191(1-3): p. 92-95.
22. Elghawail, A., et al., Prediction of springback in multi-point forming. Cogent Engineering, 2017. 4(1): p. 1400507.
23. Cao, K., Y. Wang, and Y. Wang, Experimental investigation and modeling of the tension behavior of polycarbonate with temperature effects from low to high strain rates. International Journal of Solids and Structures, 2014. 51(13): p. 2539-2548.
24. Li, Y., et al., Effects of process parameters on thickness thinning and mechanical properties of the formed parts in incremental sheet forming. The International Journal of Advanced Manufacturing Technology, 2018. 98: p. 3071-3080.
25. Abosaf, M., et al., Optimisation of multi-point forming process parameters. The International Journal of Advanced Manufacturing Technology, 2017. 92: p. 1849-1859.
26. Siviour, C., et al., Mechanical behaviour of polymers at high rates of strain. http://dx.doi.org/10.1051/jp4:2006134145, 2006. 134.
27. Sehrawat, M., et al., Glass Transition Temperature Measurement of Polycarbonate Specimen by Dynamic Mechanical Analyser Towards the Development of Reference Material. MAPAN, 2022. 37(3): p. 517-527.
28. Mulliken, A.D. and M.C. Boyce, Mechanics of the rate-dependent elastic–plastic deformation of glassy polymers from low to high strain rates. International journal of solids and structures, 2006. 43(5): p. 1331-1356.
29. Pelin, C.-E., et al., Recycling and reusing polyamide 6 extruded waste products to manufacture carbon fiber based composites. Annals of the Academy of Romanian Scientists Series on Physics and Chemistry Science, 2017. 2: p. 91-103.
30. Ayhan, Z. and Q. Zhang, Wall thickness distribution in thermoformed food containers produced by a Benco aseptic packaging machine. Polymer Engineering and Science - POLYM ENG SCI, 2000. 40: p. 1-10.
31. Dunson, D., Characterization of polymers using dynamic mechanical analysis (DMA). EAG Appl Note, 2017.
32. Sabater, M., et al., Process parameter effects on biocompatible thermoplastic sheets produced by incremental forming. Materials, 2018. 11(8): p. 1377.

Permalink -

https://repository.canterbury.ac.uk/item/9765v/optimisation-of-a-novel-hot-air-contactless-single-incremental-point-forming-of-polymers

Download files

Publisher's version
1-s2.0-S1526612524001828-main.pdf
File access level: Open

  • 58
    total views
  • 14
    total downloads
  • 1
    views this month
  • 0
    downloads this month

Export as

Related outputs

A review of corncob-based building materials as a sustainable solution for the building and construction industry
Okeke, F., Ahmed, A., Imam, A. and Hassanin, H. 2024. A review of corncob-based building materials as a sustainable solution for the building and construction industry. Hybrid Advances. 6 (100269), pp. 1-16. https://doi.org/10.1016/j.hybadv.2024.100269
A novel enhanced SOC estimation method for lithium-ion battery cells using cluster-based LSTM models and centroid proximity selection
Al-Alawi, M., Jaddoa, A., Cugley, J. and Hassanin, H. 2024. A novel enhanced SOC estimation method for lithium-ion battery cells using cluster-based LSTM models and centroid proximity selection. Journal of Energy Storage. 97 (B), p. 112866. https://doi.org/10.1016/j.est.2024.112866
Assessment of compressive strength performance of corn cob ash blended concrete: a review
Okeke, F., Ahmed, A., Imam, A. and Hassanin, H. 2024. Assessment of compressive strength performance of corn cob ash blended concrete: a review. https://doi.org/10.18552/2024/SCMT/606
Tailoring 3D star-shaped auxetic structures for enhanced mechanical performance
Hassanin, H., Wang, Y., A. Alsaleh, N., Djuansjah, J., El-Sayed, K. and Essa, K. 2024. Tailoring 3D star-shaped auxetic structures for enhanced mechanical performance. Aerospace. 11 (6), p. 428. https://doi.org/10.3390/aerospace11060428
Virtual prototyping of vision-based tactile sensors design for robotic-assisted precision machining
Zaid, I., Sajwani, H., Halwani, M., Hassanin, H., Ayyad, A., AbuAssi, A., Almaskari, F., Abdul Samad, Y, Abusafieh, A. and Zweiri, Y. 2024. Virtual prototyping of vision-based tactile sensors design for robotic-assisted precision machining. Sensors and Actuators A: Physical. 374 (115469). https://doi.org/10.1016/j.sna.2024.115469
Designing lightweight 3D-printable bioinspired structures for enhanced compression and energy absorption properties
Harish, A., A. Alsaleh, N., Ahmadein, M., Elfar, A., Djuansjah, J., Hassanin, H., El-Sayed, M. and Essa, K. 2024. Designing lightweight 3D-printable bioinspired structures for enhanced compression and energy absorption properties. Polymers. 16 (6), p. 729. https://doi.org/10.3390/polym16060729
A novel vision-based multi-functional sensor for normality and position measurements in precise robotic manufacturing
Halwani, M., Ayyad, A., AbuAssi, L., Abdulrahman, Y., Almaskari, F., Hassanin, H., Abusafieh, A. and Zweiri, Y. 2024. A novel vision-based multi-functional sensor for normality and position measurements in precise robotic manufacturing. Precision Engineering. 88, pp. 367-381. https://doi.org/10.1016/j.precisioneng.2024.02.015
Advancing safety and efficiency in critical infrastructure with a novel SOC estimation for battery storage systems: A focus on second life batteries
Al-Alawi, M., Cugley, J., Jaddoa, A. and Hassanin, H. 2024. Advancing safety and efficiency in critical infrastructure with a novel SOC estimation for battery storage systems: A focus on second life batteries.
Review on engineering of bone scaffolds using conventional and additive manufacturing technologies
Mohammed, A., Jiménez, Amaia, Bidare, Prveen, Elshaer, Amr, Memic, Adnan, Hassanin, Hany and Essa, Khamis 2024. Review on engineering of bone scaffolds using conventional and additive manufacturing technologies. 3D Printing and Additive Manufacturing. 11 (4), pp. 1418-1440. https://doi.org/10.1089/3dp.2022.0360
Contactless single point incremental forming: Experimental and numerical simulation
Almadani, M., Guner, A., Hassanin, H., De Lisi, Michele. and Essa, K. 2023. Contactless single point incremental forming: Experimental and numerical simulation. The International Journal of Advanced Manufacturing Technology. https://doi.org/10.1007/s00170-023-12401-1
Hot-air contactless single-point incremental forming
Almadani, M., Guner, A., Hassanin, H. and Essa, K. 2023. Hot-air contactless single-point incremental forming. Journal of Manufacturing and Materials Processing. 7 (5), p. 179. https://doi.org/10.3390/jmmp7050179
Optimising surface roughness and density in titanium fabrication via laser powder bed fusion
Hassanin, H., El-Sayed, M., Ahmadein, M., A. Alsaleh, N., Ataya, S., Ahmed, M. and Essa, K. 2023. Optimising surface roughness and density in titanium fabrication via laser powder bed fusion. Micromachines. 14 (8), p. 1642. https://doi.org/10.3390/mi14081642
Hybrid finite element–smoothed particle hydrodynamics modelling for optimizing cutting parameters in CFRP composites
Abena, A., Ataya, S., Hassanin, H., El-Sayed, M., Ahmadein, M., A. Alsaleh, N., Ahmed, M. and Essa, K. 2023. Hybrid finite element–smoothed particle hydrodynamics modelling for optimizing cutting parameters in CFRP composites. Polymers. 15 (13), p. 2789. https://doi.org/10.3390/polym15132789
Embracing sustainable farming: Unleashing the circular economy potential of second-life EV batteries in agricultural applications
Al-Alawi, M., Cugley, J. and Hassanin, H. 2023. Embracing sustainable farming: Unleashing the circular economy potential of second-life EV batteries in agricultural applications.
Entrained defects and mechanical properties of aluminium castings
El-Sayed, M., Essa, K. and Hassanin, H. 2023. Entrained defects and mechanical properties of aluminium castings.
Preparation of polylactic acid/calcium peroxide compo-site filaments for fused deposition modelling
Mohammed, A., Kovacev , N., Elshaer, A., Melaibari, A., Iqbal, J., Hassanin, H., Essa, K. and Memić, A. 2023. Preparation of polylactic acid/calcium peroxide compo-site filaments for fused deposition modelling. Polymers. 15 (9), p. 2229. https://doi.org/10.3390/polym15092229
Non-destructive disassembly of interference fit under wear conditions for sustainable remanufacturing
Yeung, H., Ataya, S., Hassanin, H., El-Sayed, M., Ahmadein, M., A. Alsaleh, N., Ahmed, M. and Essa, K. 2023. Non-destructive disassembly of interference fit under wear conditions for sustainable remanufacturing. Machines. 11 (5), p. 538. https://doi.org/10.3390/machines11050538
Fabrication and characterization of oxygen-generating polylactic acid/calcium peroxide composite filaments for bone scaffolds
Mohammed, A., Saeed, A., Elshaer, A., Melaibari, A., Memić, A., Hassanin, H. and Essa, K. 2023. Fabrication and characterization of oxygen-generating polylactic acid/calcium peroxide composite filaments for bone scaffolds. Pharmaceuticals. 16 (4), p. 627. https://doi.org/10.3390/ph16040627
Using second-life batteries and solar power to help farms become energy efficient.
Al-Alawi, M., Cugley, J. and Hassanin, H. 2023. Using second-life batteries and solar power to help farms become energy efficient. Canterbury Christ Church University.
Chip formation and orthogonal cutting optimisation of unidirectional carbon fibre composites
Hassanin, H., Abena, A., Soo, L., Ataya, S., El-Sayed, M., Ahmadein, M., A. Alsaleh, N., Ahmed, M. and Essa, K. 2023. Chip formation and orthogonal cutting optimisation of unidirectional carbon fibre composites. Polymers. 15 (8), p. 1897. https://doi.org/10.3390/polym15081897
Fabrication and Optimisation of Ti-6Al-4V Lattice-Structured Total Shoulder Implants Using Laser Additive Manufacturing
Bittredge, Oliver, Hassanin, H., El-Sayed, M., Eldessouky, Hossam Mohamed, A. Alsaleh, N., Alrasheedi, Nashmi H., Essa, K. and Ahmadein, M. 2022. Fabrication and Optimisation of Ti-6Al-4V Lattice-Structured Total Shoulder Implants Using Laser Additive Manufacturing. Materials (Basel, Switzerland). 15 (9), p. e3095. https://doi.org/10.3390/ma15093095
Elastomer-based visuotactile sensor for normality of robotic manufacturing systems
Hassanin, H., Zaid, I., Halwani, M., Ayyad, A., Imam, A., Almaskari, F. and Zweiri, Y. 2022. Elastomer-based visuotactile sensor for normality of robotic manufacturing systems. Polymers. 14 (23), p. 5097. https://doi.org/10.3390/polym14235097
Techno-economic feasibility of retired electric-vehicle batteries repurpose/reuse in second-life applications: A systematic review
Hassanin, H., Al-Alawi, M. and Cugley, J. 2022. Techno-economic feasibility of retired electric-vehicle batteries repurpose/reuse in second-life applications: A systematic review. Energy and Climate Change. 3 (100086). https://doi.org/10.1016/j.egycc.2022.100086
Planning, operation, and design of market-based virtual power plant considering uncertainty
Hassanin, H., Ullah, Z., Arshad, Cugley, J. and Al-Alawi, M. 2022. Planning, operation, and design of market-based virtual power plant considering uncertainty. Energies. 19 (15), p. 7290. https://doi.org/10.3390/en15197290
The epistemic insight digest: Issue : Autumn 2022
Gordon, A., Shalet, D., Simpson, S., Hassanin, H., Lawson, F., Lawson, M., Litchfield, A., Thomas, C., Canetta, E., Manley, K. and Choong, C. Shalet, D. (ed.) 2022. The epistemic insight digest: Issue : Autumn 2022. Canterbury Canterbury Christ Church University.
Modeling, optimization, and analysis of a virtual power plant demand response mechanism for the internal electricity market considering the uncertainty of renewable energy sources
Ullah, Z., Arshad and Hassanin, H. 2022. Modeling, optimization, and analysis of a virtual power plant demand response mechanism for the internal electricity market considering the uncertainty of renewable energy sources. Energies. 15 (14), p. 5296. https://doi.org/doi.org/10.3390/en15145296
Interdisciplinary engineering education - essential for the 21st century
Gordon, A., Simpson, S. and Hassanin, H. 2022. Interdisciplinary engineering education - essential for the 21st century.
Multipoint forming using hole-type rubber punch
Hassanin, H., Tolipov, A., El-Sayed, M., Eldessouky, H., A. Alsaleh, N., Alfozan, A., Essa, K. and Ahmadein, M. 2022. Multipoint forming using hole-type rubber punch. Metals. 12 (3), p. 491. https://doi.org/10.3390/met12030491
Influence of bifilm defects generated during mould filling on the tensile properties of Al−Si−Mg cast alloys
El-Sayed, M., Essa, K. and Hassanin, H. 2022. Influence of bifilm defects generated during mould filling on the tensile properties of Al−Si−Mg cast alloys. Metals. 12 (1), p. e160. https://doi.org/10.3390/met12010160
Multistage Tool Path Optimisation of Single-Point Incremental Forming Process
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
Effect of runner thickness and hydrogen content on the mechanical properties of A356 alloy castings
El-Sayed, M., Essa, K. and Hassanin, H. 2021. Effect of runner thickness and hydrogen content on the mechanical properties of A356 alloy castings . International Journal of Metalcasting. https://doi.org/10.1007/s40962-021-00753-x
Parts design and process optimization
Hassanin, Hany, Bidare, Prveen, Zweiri, Yahya and Essa, Khamis 2021. Parts design and process optimization. in: Salunkhe, S., Hussein, H. and Davim, J. (ed.) Applications of Artificial Intelligence in Additive Manufacturing USA IGI Global. pp. 25-49
Micro-additive manufacturing technologies of three-dimensional MEMS
Hassanin, H., Sheikholeslami, G., Pooya, S. and Ishaq, R. 2021. Micro-additive manufacturing technologies of three-dimensional MEMS . Advanced Engineering Materials. https://doi.org/10.1002/adem.202100422
Machine learning applied to the design and inspection of reinforced concrete bridges: Resilient methods and emerging applications
Fan , W., Chen, Y., Li, J., Sun, Y., Feng, F., Hassanin, H. and Sareh, P. 2021. Machine learning applied to the design and inspection of reinforced concrete bridges: Resilient methods and emerging applications. Structures. 33, pp. 3954-3963. https://doi.org/10.1016/j.istruc.2021.06.110
Porosity, cracks, and mechanical properties of additively manufactured tooling alloys: A review
Bidare, P., Jiménez, A., Hassanin, H. and Essa, K. 2021. Porosity, cracks, and mechanical properties of additively manufactured tooling alloys: A review. Advances in Manufacturing. https://doi.org/10.1007/s40436-021-00365-y
Laser powder bed fusion of Ti-6Al-2Sn-4Zr-6Mo alloy and properties prediction using deep learning approaches
Hassanin, H., Zweiri, Y., Finet, L., Essa, K., Qiu, C. and Attallah, M. 2021. Laser powder bed fusion of Ti-6Al-2Sn-4Zr-6Mo alloy and properties prediction using deep learning approaches. Materials. 14 (8), p. 2056. https://doi.org/10.3390/ma14082056
3DP printing of oral solid formulations: a systematic review
Brambilla, C., Okafor-Muo, O., Hassanin, H. and ElShaer, A. 2021. 3DP printing of oral solid formulations: a systematic review. Pharmaceutics. 13 (3), p. 358. https://doi.org/10.3390/pharmaceutics13030358
Powder-based laser hybrid additive manufacturing of metals: A review
Hassanin, H. 2021. Powder-based laser hybrid additive manufacturing of metals: A review. The International Journal of Advanced Manufacturing Technology.
Micro-fabrication of ceramics: additive manufacturing and conventional technologies
Hassanin, H., Essa, K., Elshaer, A., Imbaby, M. and El-Sayed, T. E. 2021. Micro-fabrication of ceramics: additive manufacturing and conventional technologies. Journal of Advanced Ceramics. 10, pp. 1-27. https://doi.org/10.1007/s40145-020-0422-5
4D Printing of origami structures for minimally invasive surgeries using functional scaffold
Langford, T, Mohammed, A., Essa, K., Elshaer, A. and Hassanin, H. 2020. 4D Printing of origami structures for minimally invasive surgeries using functional scaffold. Applied Sciences. 11 (1), p. 332. https://doi.org/10.3390/app11010332
Reconfigurable multipoint forming using waffle-type elastic cushion and variable loading profile
Hassanin, H., Mohammed, M., Abdel-Wahab, A. and Essa, K 2020. Reconfigurable multipoint forming using waffle-type elastic cushion and variable loading profile. Materials.
3D printing of solid oral dosage forms: numerous challenges with unique opportunities
Hassanin, H. 2020. 3D printing of solid oral dosage forms: numerous challenges with unique opportunities. Journal of Pharmaceutical Sciences. https://doi.org/10.1016/j.xphs.2020.08.029
Design optimisation of additively manufactured titanium lattice structures for biomedical implants
El-Sayed, M.A., Essa, K., Ghazy, M. and Hassanin, H. 2020. Design optimisation of additively manufactured titanium lattice structures for biomedical implants. The International Journal of Advanced Manufacturing Technology. https://doi.org/10.1007/s00170-020-05982-8
4D Printing of NiTi auxetic structure with improved ballistic performance
Hassanin, H., Abena, A., Elsayed, M.A. and Essa, K. 2020. 4D Printing of NiTi auxetic structure with improved ballistic performance. Micromachines. 11 (8), p. 745. https://doi.org/doi.org/10.3390/mi11080745