Prediction of formation force during single-point incremental sheet metal forming using artificial intelligence techniques

Al-Samhan, Ali M.; Ragab, Adham E.; Dabwan, Abdulmajeed; Nasr, Mustafa M.; Hidri, Lotfi

doi:10.1371/journal.pone.0221341

Cited by 31 publications

(15 citation statements)

References 25 publications

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“…The optimum process parameters in SPIF were obtained and validated through these experiments, and highly satisfactory results were found with an error of less than 10%. Alsaman et al [ 32 ] applied ANNs and the regression model to analyse the SPIF process for conical draw pieces. Najm and Paniti [ 4 ] used ANNs to predict the Ra and Rz parameters by adopting the data collected from frustum cones that were formed by SPIF.…”

Section: Introductionmentioning

confidence: 99%

Surface Finish Analysis in Single Point Incremental Sheet Forming of Rib-Stiffened 2024-T3 and 7075-T6 Alclad Aluminium Alloy Panels

et al. 2021

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The article presents the results of the analysis of the interactions between the single point incremental forming (SPIF) process parameters and the main roughness parameters of stiffened ribs fabricated in Alclad aluminium alloy panels. EN AW-7075-T6 and EN AW-2024-T3 Alclad aluminium alloy sheets were used as the research material. Panels with longitudinal ribs were produced with different values of incremental vertical step size and tool rotational speed. Alclad is formed of high-purity aluminium surface layers metallurgically bonded to aluminium alloy core material. The quality of the surface roughness and unbroken Alclad are key problems in SPIF of Alclad sheets destined for aerospace applications. The interactions between the SPIF process parameters and the main roughness parameters of the stiffened ribs were determined. The influence of forming parameters on average roughness Sa and the 10-point peak–valley surface roughness Sz was determined using artificial neural networks. The greater the value of the incremental vertical step size, the more prominent the ridges found in the inner surface of stiffened ribs, especially in the case of both Alclad aluminium alloy sheets. The predictive models of ANNs for the Sa and the Sz were characterised by performance measures with R2 values lying between 0.657 and 0.979. A different character of change in surface roughness was found for sheets covered with and not covered with a soft layer of technically pure aluminium. In the case of Alclad sheets, increasing the value of the incremental vertical step size increases the value of the surface roughness parameters Sa and Sz. In the case of the sheets not covered by Alclad, reduction of the tool rotational speed increases the Sz parameter and decreases the Sa parameter. An obvious increase in the Sz parameter was observed with an increase in the incremental vertical step size.

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Section: Introductionmentioning

confidence: 99%

Surface Finish Analysis in Single Point Incremental Sheet Forming of Rib-Stiffened 2024-T3 and 7075-T6 Alclad Aluminium Alloy Panels

et al. 2021

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“…e greater wear in the smaller tool is caused by contact forces acting on a smaller area resulting in higher stresses when compared to larger tools. It can be seen in Figure 13 that the forming forces applied on the small tool are higher than that of the bigger tool even when all the other process parameters are constant [38,39]. Also Figure 14 shows that the initial roughness of the two SPIF tools is almost the same.…”

Section: Analysis Of Surfacementioning

confidence: 99%

Study of the Effect of Process Parameters on Surface Profile Accuracy in Single-Point Incremental Sheet Forming of AA1050-H14 Aluminum Alloy

Dabwan

Ragab

Saleh³

et al. 2020

Advances in Materials Science and Engineering

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Single-point incremental forming is an innovative flexible and inexpensive technique to form sheet products when prototypes or small batches are required. The process allows complex geometries to be produced using a computer numerical control machine, eliminating the need for a special die. This study reports on the effects of four important single-point incremental forming process parameters on produced surface profile accuracies. The profile accuracy was estimated by measuring the side angle errors and surface roughness and also waviness and circularity of the product inner surface. Full factorial design of experiments was used to plan the study, and the analysis of variance was used to analyze and interpret the results. The results indicate that the tool diameter (d), step depth (s), and sheet thickness (t) have significant effects on the produced profile accuracy, while the feed rate (f) is not significant. As a general rule, thin sheets with greater tool diameters yielded the best surface quality. The results also show that controlling all surface quality features is complex because of the contradicting effects of, and interactions between, a number of the process parameters.

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“…6 involves the deformation of sheet metal along a path of contour lines using a ball-nose tool. In order to study the significance of its process parameters on forming depth, 7 thinning, 8 stresses, 9 strains, 10,11 surface quality, 12 forming force, 13,14 and geometric accuracy 15,16 of the fabricated part, extensive research has been carried out.…”

Section: Introductionmentioning

confidence: 99%

Multiobjective optimization of process variables in single-point incremental forming using grey relational analysis coupled with entropy weights

Dabwan

Ragab

Saleh³

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part L:

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Incremental sheet forming is a specific group of sheet forming methods that enable the manufacture of complex parts utilizing computer numerical control instead of specialized tools. It is an incredibly adaptable operation that involves minimal usage of sophisticated tools, dies, and forming presses. Besides its main application in the field of rapid prototyping, incremental sheet forming processes can be used for the manufacture of unique parts in small batches. The goal of this study is to broaden the knowledge of the deformation process in single-point incremental forming. This work studies the deformation behavior in single-point incremental forming by experimentally investigating the principal stresses, principal strains, and thinning of single-point incremental forming products. Conical-shaped components are fabricated using AA1050-H14 aluminum alloy at various combinations of fundamental variables. The factorial design is employed to plan the experimental study and analysis of variance is conducted to analyze the results. The grey relational analysis approach coupled with entropy weights is also implemented to identify optimum process variables for single-point incremental forming. The results show that the tool diameter has the greatest effect on the thinning of the SPIF product, followed by the sheet thickness, step size, and feed rate.

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Prediction of formation force during single-point incremental sheet metal forming using artificial intelligence techniques

Cited by 31 publications

References 25 publications

Surface Finish Analysis in Single Point Incremental Sheet Forming of Rib-Stiffened 2024-T3 and 7075-T6 Alclad Aluminium Alloy Panels

Surface Finish Analysis in Single Point Incremental Sheet Forming of Rib-Stiffened 2024-T3 and 7075-T6 Alclad Aluminium Alloy Panels

Study of the Effect of Process Parameters on Surface Profile Accuracy in Single-Point Incremental Sheet Forming of AA1050-H14 Aluminum Alloy

Multiobjective optimization of process variables in single-point incremental forming using grey relational analysis coupled with entropy weights

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