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 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 st...

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