Multipoint forming using hole-type rubber punch.

Tolipov, Abror; Hassanin, Hany; El-Sayed, Mahmoud Ahmed; Eldessouky, Hossam Mohamed; Alsaleh, Naser A.; Alfozan, Adel Khalid; Essa, Khamis; Ahmadein, Mahmoud

Abstract

Reconfigurable multipoint forming is a flexible sheet forming technique aimed at customised sheet metal products. However, one drawback of multipoint forming is the cost and time needed to set up and align the upper and lower pin matrices. This study introduces an optimisation study of a novel hole-type rubber punch replacing the top pin matrix of multipoint incremental forming, aiming to reduce pins setting up and alignment complexity and time. Finite element modelling and design of experiments were used to investigate the effect of hole-type rubber punch configuration such as hole size, hole type, and the compression ratio on the wrinkling, thickness variation, and shape deviation. This research shows that the most significant process parameter in all responses was the hole size. The compression ratio of the material was found to be insignificant in wrinkling and shape deviation. The hole-type rubber punch parameters were found to be a hole size of 9 mm, circular hole type, and a compression ratio of 75%. This experimentally resulted in an improved parts wrinkling of 80%, when compared to using solid rubber punch, with the added benefits of reduction of the cost and time needed to set up and align the pin matrices.

Citation

TOLIPOV, A., HASSANIN, H., EL-SAYED, M.A., ELDESSOUKY, H.M., ALSALEH, N.A., ALFOZAN, A.K., ESSA, K. and AHMADEIN, M. 2022. Multipoint forming using hole-type rubber punch. Metals [online], 12(3), article number 491. Available from: https://doi.org/10.3390/met12030491

• Journal Article Type: Article
• Acceptance Date: Mar 7, 2022
• Online Publication Date: Mar 14, 2022
• Publication Date: Mar 31, 2022
• Deposit Date: Feb 13, 2025
• Publicly Available Date: Feb 20, 2025
• Journal: Metals
• Electronic ISSN: 2075-4701
• Publisher: MDPI
• Peer Reviewed: Peer Reviewed
• Volume: 12
• Issue: 3
• Article Number: 491
• DOI: https://doi.org/10.3390/met12030491
• Keywords: Multipoint forming; Finite-element modelling; Design of experiments; Sheet metal forming
• Public URL: https://rgu-repository.worktribe.com/output/2702319