Modelling and optimal design of sheet metal RP&M processes

Purpose - To study the influence of process and product parameters on the properties of products in incremental sheet metal-forming; to create models for process optimisation and to introduce an approach to incremental forming process optimisation.Design methodology approach - A new flexible sheet m...

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Bibliographic Details
Published in:Rapid prototyping journal 2005-01, Vol.11 (5), p.304-311
Main Authors: Pohlak, Meelis, Küttner, Rein, Majak, Jüri
Format: Article
Language:English
Subjects:
Design
Design optimization
Finite element analysis
Mathematical programming
Metals
Optimal control
Production methods
Prototypes
Rapid prototyping
Sheet metal
Studies
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Summary:Purpose - To study the influence of process and product parameters on the properties of products in incremental sheet metal-forming; to create models for process optimisation and to introduce an approach to incremental forming process optimisation.Design methodology approach - A new flexible sheet metal-forming technique, incremental forming, has been studied. The technique can be viewed as a rapid prototyping manufacturing technique for sheet metal parts. To analyse the process, an experimental study and finite element analysis were performed. For the optimal design of incremental forming process non-linear mathematical programming was used. To estimate the limitations and main parameters of the process, a complex model was developed.Findings - Introducing optimisation procedures for the incremental forming process allows users to increase productivity and to assure quality.Research limitations implications - As finite element analysis of the process is time-consuming in real life situations, a future study should include creating analytical models for process modelling.Practical implications - The described approach can be used in practice to improve competitiveness of companies producing sheet metal prototypes.Originality value - This paper offers guidelines for shortening processing time of sheet metal prototypes for engineers and researchers. The optimisation that is based on experimental theoretical numerical models of incremental forming process has not been covered before in the scientific literature.
ISSN:1355-2546
1758-7670
DOI:10.1108/13552540510623620