Multipoint forming using mesh-type elastic cushion: modelling and experimentation

  • A. Tolipov
  • A. Elghawail
  • M. Abosaf
  • D. Pham
  • H. Hassanin
  • K. EssaEmail author
Open Access


There is a growing demand for flexible manufacturing techniques that meet the rapid changes in production technology, processes and innovations. Multipoint forming (MPF) is a flexible sheet metal forming technique where a reconfigurable die can be readily changed to produce various shapes. Parts produced using MPF suffer from geometrical defects such as wrinkling, dimpling and thickness variations. In this paper, a multipoint forming process using a novel mesh-type elastic cushion was proposed in order to improve the quality of the deformed sheet and to minimise the developed defects. Finite element modelling (FEM) and design of experiments (DoE) were used to study the influence of the mesh-type elastic cushion parameters such as the type and the size of the mesh, and the thickness of the cushion on the wrinkling, deviation and thickness variations of the deformed sheet. The results showed that using elastic cushion with square meshes of a size of 3.5 mm and a thickness of 3 mm reduced the wrinkling from 3.18 to 1.98 mm, while the thickness variation improved from 98 to 19 μm. Finally, the deviation from target shape reduced from 1.7848 to 0.0358 mm.


Multipoint forming Mesh-type elastic cushion Modelling Design of experiment 



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© The Author(s) 2019

Open Access This article is distributed under the terms of the Creative Commons Attribution 4.0 International License (, which permits unrestricted use, distribution, and reproduction in any medium, provided you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license, and indicate if changes were made.

Authors and Affiliations

  • A. Tolipov
    • 1
  • A. Elghawail
    • 1
  • M. Abosaf
    • 1
  • D. Pham
    • 1
  • H. Hassanin
    • 2
  • K. Essa
    • 1
    Email author
  1. 1.Department of Mechanical Engineering, School of EngineeringUniversity of BirminghamBirminghamUK
  2. 2.School of EngineeringUniversity of LiverpoolLiverpoolUK

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