Multistage Tool Path Optimisation of Single-Point Incremental Forming Process

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 t...

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Autores principales:	Zhou Yan, Hany Hassanin, Mahmoud Ahmed El-Sayed, Hossam Mohamed Eldessouky, JRP Djuansjah, Naser A. Alsaleh, Khamis Essa, Mahmoud Ahmadein
Formato:	article
Lenguaje:	EN
Publicado:	MDPI AG 2021
Materias:	SPIF sheet metal forming incremental FEA tool path Technology T Electrical engineering. Electronics. Nuclear engineering TK1-9971 Engineering (General). Civil engineering (General) TA1-2040 Microscopy QH201-278.5 Descriptive and experimental mechanics QC120-168.85
Acceso en línea:	https://doaj.org/article/44945c4038414591821f0927ae23fce4
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spelling	oai:doaj.org-article:44945c4038414591821f0927ae23fce42021-11-25T18:13:38ZMultistage Tool Path Optimisation of Single-Point Incremental Forming Process10.3390/ma142267941996-1944https://doaj.org/article/44945c4038414591821f0927ae23fce42021-11-01T00:00:00Zhttps://www.mdpi.com/1996-1944/14/22/6794https://doaj.org/toc/1996-1944Single-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.Zhou YanHany HassaninMahmoud Ahmed El-SayedHossam Mohamed EldessoukyJRP DjuansjahNaser A. AlsalehKhamis EssaMahmoud AhmadeinMDPI AGarticleSPIFsheet metalformingincrementalFEAtool pathTechnologyTElectrical engineering. Electronics. Nuclear engineeringTK1-9971Engineering (General). Civil engineering (General)TA1-2040MicroscopyQH201-278.5Descriptive and experimental mechanicsQC120-168.85ENMaterials, Vol 14, Iss 6794, p 6794 (2021)
institution	DOAJ
collection	DOAJ
language	EN
topic	SPIF sheet metal forming incremental FEA tool path Technology T Electrical engineering. Electronics. Nuclear engineering TK1-9971 Engineering (General). Civil engineering (General) TA1-2040 Microscopy QH201-278.5 Descriptive and experimental mechanics QC120-168.85
spellingShingle	SPIF sheet metal forming incremental FEA tool path Technology T Electrical engineering. Electronics. Nuclear engineering TK1-9971 Engineering (General). Civil engineering (General) TA1-2040 Microscopy QH201-278.5 Descriptive and experimental mechanics QC120-168.85 Zhou Yan Hany Hassanin Mahmoud Ahmed El-Sayed Hossam Mohamed Eldessouky JRP Djuansjah Naser A. Alsaleh Khamis Essa Mahmoud Ahmadein Multistage Tool Path Optimisation of Single-Point Incremental Forming Process
description	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.
format	article
author	Zhou Yan Hany Hassanin Mahmoud Ahmed El-Sayed Hossam Mohamed Eldessouky JRP Djuansjah Naser A. Alsaleh Khamis Essa Mahmoud Ahmadein
author_facet	Zhou Yan Hany Hassanin Mahmoud Ahmed El-Sayed Hossam Mohamed Eldessouky JRP Djuansjah Naser A. Alsaleh Khamis Essa Mahmoud Ahmadein
author_sort	Zhou Yan
title	Multistage Tool Path Optimisation of Single-Point Incremental Forming Process
title_short	Multistage Tool Path Optimisation of Single-Point Incremental Forming Process
title_full	Multistage Tool Path Optimisation of Single-Point Incremental Forming Process
title_fullStr	Multistage Tool Path Optimisation of Single-Point Incremental Forming Process
title_full_unstemmed	Multistage Tool Path Optimisation of Single-Point Incremental Forming Process
title_sort	multistage tool path optimisation of single-point incremental forming process
publisher	MDPI AG
publishDate	2021
url	https://doaj.org/article/44945c4038414591821f0927ae23fce4
work_keys_str_mv	AT zhouyan multistagetoolpathoptimisationofsinglepointincrementalformingprocess AT hanyhassanin multistagetoolpathoptimisationofsinglepointincrementalformingprocess AT mahmoudahmedelsayed multistagetoolpathoptimisationofsinglepointincrementalformingprocess AT hossammohamedeldessouky multistagetoolpathoptimisationofsinglepointincrementalformingprocess AT jrpdjuansjah multistagetoolpathoptimisationofsinglepointincrementalformingprocess AT naseraalsaleh multistagetoolpathoptimisationofsinglepointincrementalformingprocess AT khamisessa multistagetoolpathoptimisationofsinglepointincrementalformingprocess AT mahmoudahmadein multistagetoolpathoptimisationofsinglepointincrementalformingprocess
_version_	1718411434370531328

Multistage Tool Path Optimisation of Single-Point Incremental Forming Process

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