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.
Abebe M, Lee K, Kang BS (2016) Surrogate-based multi-point forming process optimization for dimpling and wrinkling reduction. Int J Adv Manuf Technol 85:391–403
Abosaf M, Essa K, Alghawail A, Tolipov A, Su S, Pham D (2017) Optimisation of multi-point forming process parameters. Int J Adv Manuf Technol 92:1849–1859
Alhameedi A.k., 2013, Influence of die elements shapes on process parameters in multi-point sheet metal forming process,.
Cai Z-Y, Wang S-H, Li M-Z (2008) Numerical investigation of multi-point forming process for sheet metal: wrinkling, dimpling and springback. Int J Adv Manuf Technol 37:927–936
Chen J-J, Li M-Z, Liu W, Wang C-T (2005) Sectional multipoint forming technology for large-size sheet metal. Int J Adv Manuf Technol 25:935–939
Chen J, Fu W, Li M, Wang Y, Deng Y , 2017 Research on formability of multi-point press forming for 08Al and 2024-O sheet, In: Key Eng Mater, , pp.:12e4–132.
Elghawail A, Essa K, Abosaf M, Tolipov A, Su S, Pham D (2017) Prediction of springback in multi-point forming. Cogent Eng 4:1400507. https://doi.org/10.1080/23311916.2017.1400507
Elghawail A, Essa K, Abosaf M, Tolipov A, Su S, Pham D (2018) Low-cost metal-forming process using an elastic punch and a reconfigurable multi-pin die. Int J Mater Form
Erhu Q, Mingzhe L, Rui L, Liang Z, Zhuo Y (2018) Inhibitory effects of a flexible steel pad on wrinkling in multi-point die forming. Int J Adv Manuf Technol 95:2413–2420
Essa K, Hassanin H, Attallah MM, Adkins NJ, Musker AJ, Roberts GT, Tenev N, Smith M (2017) Development and testing of an additively manufactured monolithic catalyst bed for HTP thruster applications. Appl Catal A Gen 542:125–135
Galatas A, Hassanin H, Zweiri Y, Seneviratne L (2018) Additive manufactured sandwich composite/ABS parts for unmanned aerial vehicle applications. Polymers 10:1262
Hassanin H, Modica F, El-Sayed MA, Liu J, Essa K (2016) Manufacturing of Ti–6Al–4V micro-implantable parts using hybrid selective laser melting and micro-electrical discharge machining. Adv Eng Mater 18:1544–1549
Hassanin H, Finet L, Cox SC, Jamshidi P, Grover LM, Shepherd DET, Addison O, Attallah MM (2018) Tailoring selective laser melting process for titanium drug-delivering implants with releasing micro-channels. Addit Manuf 20:144–155
Nakajima N (1969) A newly developed technique to fabricate complicated dies and electrodes with wires. Bulletin of JSME 12:1546–1554
Park J-W, Kim Y-B, Kim J, Kang B-S (2014) Study on multiple die stretch forming for curved surface of sheet metal. Int J Precis Eng Manuf 15:2429–2436
Paunoiu V, Cekan P, Gavan E, Nicoara D (2008) Numerical simulations in reconfigurable multipoint forming. Int J Mater Form 1:181–184
Paunoiu VTV, Maier C, Baroiu N, Bercu G, (2011), Study of the tool geometry in reconfigurable multipoint forming, The Annals of Dunărea de Jos University of Galaţi, Fascicle V, Technologies In Machine Building:1221–4566.
Peng H, Liu H, Zhang X (2017) Numerical investigation of wrinkle for multi-point thermoforming of polymethylmethacrylate sheet. IOP Conference Series: materials science and engineering 242:012028
Quan G-Z, Ku T-W, Kang B-S (2011) Improvement of formability for multi-point bending process of AZ31B sheet material using elastic cushion. Int J Precis Eng Manuf 12:1023–1030
Tolipov AA, Elghawail A, Shushing S, Pham D, Essa K (2017) Experimental research and numerical optimisation of multi-point sheet metal forming implementation using a solid elastic cushion system. J Phys Conf Ser 896:012120
Valjavec M, Hardt DE (1999) Closed-loop shape control of the stretch forming process over a reconfigurable tool: precision airframe skin fabrication. Peroceedings of ICEME 99:1–11
Wang S, Cai Z, Li M, Lan Y (2012) Numerical simulation on the local stress and local deformation in multi-point stretch forming process. Int J Adv Manuf Technol 60:901–911
Zareh-Desari B, Davoodi B, Vedaei-Sabegh A (2017) Investigation of deep drawing concept of multi-point forming process in terms of prevalent defects. Int J Mater Form 10:193–203
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
About this article
Cite this article
Tolipov, A., Elghawail, A., Abosaf, M. et al. Multipoint forming using mesh-type elastic cushion: modelling and experimentation. Int J Adv Manuf Technol 103, 2079–2090 (2019). https://doi.org/10.1007/s00170-019-03635-z
- Multipoint forming
- Mesh-type elastic cushion
- Design of experiment