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Related Experiment Video

Updated: Oct 12, 2025

A Soft Tooling Process Chain for Injection Molding of a 3D Component with Micro Pillars
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Multistage Tool Path Optimisation of Single-Point Incremental Forming Process.

Zhou Yan1, Hany Hassanin2, Mahmoud Ahmed El-Sayed3

  • 1School of Engineering, University of Birmingham, Birmingham B152TT, UK.

Materials (Basel, Switzerland)
|November 27, 2021
PubMed
Summary
This summary is machine-generated.

This study optimized the two-stage single-point incremental forming (SPIF) process, significantly reducing geometrical inaccuracies and processing time for customized sheet metal production. The optimized SPIF strategy improved part accuracy by 25% and cut forming time by over 55%.

Keywords:
FEASPIFformingincrementaloptimisationsheet metaltool path

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Area of Science:

  • Manufacturing Engineering
  • Materials Science
  • Mechanical Engineering

Background:

  • Single-point incremental forming (SPIF) is a versatile die-less technology for customized sheet metal production.
  • SPIF offers cost-effectiveness for small-batch manufacturing but suffers from geometrical inaccuracies and thickness variations.
  • Optimizing SPIF is crucial for enhancing its industrial applicability.

Purpose of the Study:

  • To optimize a two-stage SPIF strategy for improved geometrical accuracy and reduced processing time.
  • To investigate the influence of forming parameters on part quality in a two-stage SPIF process.
  • To validate the optimized strategy through finite element analysis and statistical methods.

Main Methods:

  • Finite element analysis (FEA) was employed and validated against experimental data.
  • A design of experiments (DoE) approach was utilized for parameter optimization.
  • Mass scaling technique was applied in FEA to reduce computational time.

Main Results:

  • The step size in the second forming stage significantly impacted geometrical accuracy.
  • Forming depth in the first stage had minimal effect on the final part quality.
  • Optimized SPIF reduced geometrical deviation by 25% and forming time by 55.56%.

Conclusions:

  • The optimized two-stage SPIF strategy effectively enhances part accuracy and reduces production time.
  • Improvements were most notable in the base and wall regions of the formed parts.
  • This research provides a pathway for more efficient and accurate die-less forming.