Article
Automation & Control Systems
Zhigang Liu, Dharmesh Kumar, Suwat Jirathearanat, Wei Hin Wong
Summary: In this paper, a multiple-tool (MT) modeling method is proposed to reduce computational time for finite element simulations of incremental sheet forming (ISF) process. The method demonstrates enhanced computation efficiency and prediction accuracy for thickness reduction and springback of ISF parts. Experimental validation and comparison with traditional methods confirm the feasibility and adaptability of the proposed MT simulation method for complex ISF parts. This study provides important guidelines for the use of FE simulation in the design and fabrication of large industrial-scale ISF parts.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Automation & Control Systems
Zhigang Liu, Dharmesh Kumar, Suwat Jirathearanat, Wei Hin Wong
Summary: In this paper, a multiple-tool (MT) modeling method was proposed to reduce computational time for finite element simulations of incremental sheet forming (ISF) process. The aim was to investigate the computation efficiency and prediction accuracy of thickness reduction and springback of ISF parts using the MT simulation model. The results showed that the proposed MT method can significantly reduce CPU time and maintain geometric accuracy in tolerance, although it differs physically from the real forming process of single-tool ISF.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Materials Science, Multidisciplinary
Hyung-Rim Lee, Myoung-Gyu Lee, Namsu Park
Summary: In this study, a novel incremental tube forming (ITF) process is proposed to overcome the material loss issue in conventional forming processes. The new process successfully produces complex-profiled S-shaped tube components, and the feasibility of the process is confirmed through numerical analysis.
METALS AND MATERIALS INTERNATIONAL
(2022)
Article
Automation & Control Systems
Liangchi Zhang, Chuhan Wu, Hossein Sedaghat
Summary: This paper presents a thorough investigation on incremental sheet metal forming assisted by ultrasonic vibration. Utilizing a new acoustoplasticity constitutive model, the study conducted extensive numerical analyses and experimental investigations to examine the effects of critical parameters on forming force, sheet thickness reduction, and springback. The models were found to accurately predict the sheet metal forming process under ultrasonic vibration, with potential to advance ultrasonic vibration-assisted forming techniques.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Engineering, Mechanical
Kijung Lee, Jinheung Park, Jinwoo Lee, Soon Woo Kwon, Insuk Choi, Myoung-Gyu Lee
Summary: A micromechanics-based friction model is proposed to improve an existing surface asperity-based friction model. The model considers the equilibrium between the plastically deformable workpiece and contact tool, and implements the plowing effect through a newly proposed geometrical modeling of the tool surface. The model is validated by comparing the calculated friction coefficients with experimental results and is then implemented in finite element software to simulate forming processes.
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
(2023)
Article
Multidisciplinary Sciences
Trunal Bhujangrao, Fernando Veiga, Mariluz Penalva, Adriana Costas, Cristina Ruiz
Summary: This paper presents a process analysis of manufacturing parts by metal forming using a finite element model. It provides guidelines for manufacturing based on the correct set of parameters.
Article
Engineering, Electrical & Electronic
Ali Abdelhafeez Hassan, Gokhan Kucukturk, Hurcan Volkan Yazgin, Hakan Gurun, Duran Kaya
Summary: This study compares three different material models for PA-SPIF process and finds that the fracture-forming-limit diagram (FFLD) material model is most accurate according to the experimental results.
Article
Chemistry, Physical
Zhou Yan, Hany Hassanin, Mahmoud Ahmed El-Sayed, Hossam Mohamed Eldessouky, J. R. P. Djuansjah, Naser A. Alsaleh, Khamis Essa, Mahmoud Ahmadein
Summary: Single-point incremental forming (SPIF) is a flexible technology suitable for small and medium customised production. Despite some drawbacks such as geometrical inaccuracy and thickness uniformity issues, these can be reduced through optimization.
Article
Engineering, Manufacturing
D. Sorgente, A. Lombardi, D. Coviello, L. D. Scintilla, M. Fontana
Summary: Superplastic forming is an advanced sheet metal forming process commonly used in aerospace, automotive, and biomedical applications for its capacity to replicate complex geometries. Understanding tribological issues, especially the evaluation of the coefficient of friction, is crucial for successful results and tool longevity. This study proposes a new test method and attempts to evaluate strain-dependent values of COF through a mathematical model, using experimental and numerical results for calibration.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Engineering, Industrial
Harish Kumar Nirala, Anupam Agrawal
Summary: This paper focuses on the formability response of the sheet stretching during the Incremental Sheet Forming (ISF) process. The stretching primarily depends on the wall angle and incremental depth. The study investigates the effect of different geometries on sheet stretching and proposes an adaptive increment based strategy for achieving uniform sheet stretching. Experimental and simulation results show improvements in sheet thickness and stress distribution.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2022)
Article
Computer Science, Artificial Intelligence
Luka Sevsek, Sandi Baressi Segota, Zlatan Car, Tomaz Pepelnjak
Summary: Single-point incremental forming (SPIF) is a process that uses a small tool to move along a trajectory and form a fix-clamped sheet metal into the desired shape. To improve the thinning issue resulting in fracture, a two-step forming method combining pre-bulging and SPIF is proposed. This study analyzed the SPIF process and the hybrid two-step forming using simulation and the random forest method, and found significant influences of the workpiece wall angle, part depth, and initial sheet thickness on thinning and forming force components.
APPLIED SOFT COMPUTING
(2023)
Article
Engineering, Manufacturing
Xiao Xiao, Jin-Jae Kim, Seok-Hwan Oh, Young-Suk Kim
Summary: A hybrid incremental sheet-forming technique for carbon fiber reinforced thermosets (CFRTS) was developed and applied, showing promising results for both single- and multi-layer prepregs. Finite element simulations accurately predicted the deformation shape and shear angle of the CFRP sheet during the incremental sheet forming (ISF) process, indicating the effectiveness of the proposed forming strategy.
COMPOSITES PART A-APPLIED SCIENCE AND MANUFACTURING
(2021)
Article
Automation & Control Systems
Mohammad Mehdi Kasaei, Hassan Moslemi Naeini, Behnam Abbaszadeh, Amir H. Roohi, Maria Beatriz Silva, Paulo A. F. Martins
Summary: This paper revisited the deformation mechanics of flexible roll forming process and proposed a new criterion based on wrinkling limit curve to predict wrinkling in finite element analysis. The new criterion showed successful prediction of wrinkling onset and is recommended for predicting wrinkling in sheet metal forming processes.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Materials Science, Multidisciplinary
Kinya Nakagawa, Yuji Yamasaki, Yoshikiyo Tamai, Jiro Hiramoto
Summary: Improving the formability of steel sheets is crucial for manufacturing complicated car parts. Multistep forming has been identified as a method to enhance formability. This study investigates the relationship between the shape after preforming and the forming limit in the main forming process by forming circular truncated cones using a two-step forming process. The results show that the forming limit in main forming is affected by the shape after preforming, specifically determined by the central cross-sectional line length.
MATERIALS TRANSACTIONS
(2022)
Review
Chemistry, Physical
Valentin Oleksik, Tomasz Trzepiecinski, Marcin Szpunar, Lukasz Chodola, Daniel Ficek, Ireneusz Szczesny
Summary: Incremental sheet forming of titanium and its alloys plays a significant role in modern manufacturing industry by producing high-quality, complex-shaped products at low cost. The development of single-point incremental forming technique in titanium alloys, especially for difficult-to-form types, is highlighted, with potential applications in various industries, particularly in the medical field. The need for appropriate lubrication in the forming process of titanium alloys is emphasized due to their unfavorable tribological properties. Insufficient research on the synergistic effect of rotational speed and tool rotation direction on surface roughness of workpieces was also noted in the literature review.
Article
Computer Science, Artificial Intelligence
Wenjie Wang, Guangdong Tian, Gang Yuan, Duc Truong Pham
Summary: This article studies the scheduling problem for a remanufacturing system with parallel disassembly workstations, parallel flow-shop-type reprocessing lines and parallel reassembly workstations. An improved multi-objective invasive weed optimization algorithm is utilized to address the multi-objective optimization problem, and the effectiveness of the algorithm is validated through numerical experiments and a practical case.
JOURNAL OF INTELLIGENT MANUFACTURING
(2023)
Article
Automation & Control Systems
Mairi Kerin, Duc Truong Pham, Jun Huang, Jeremy Hadall
Summary: This article discusses the application of digital twins in the manufacturing industry and focuses on the development of product digital twins to reduce uncertainties in remanufacturing. By proposing functional requirements and a modeling language model, the importance of digital twins in remanufacturing process planning is demonstrated.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Review
Automation & Control Systems
Weining Li, Moataz M. Attallah, Khamis Essa
Summary: Single-point incremental forming (SPIF) is a sheet forming technique that gradually deforms sheet materials to a designated shape. It has shown high capability to deform low-strength materials accurately at room temperature. However, deforming high-temperature alloys requires integrated heating sources, which can lead to unpredictable thermal behaviors and affect formability and surface quality. The current challenge is improving localized and stable heating, tool design to reduce thermal expansion and friction, and analyzing the relationship between thermal and mechanical effects.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Automation & Control Systems
Shizhong Su, Duc Truong Pham, Chunqian Ji, Yongjing Wang, Jun Huang, Wei Zhou, Haolin Wang
Summary: This paper presents the design of a compliant robot end-of-arm tool for removing pegs from tightly fitting holes in mechanical products during disassembly operations. The tool reduces stress at the contact points between the peg and the hole, minimizing the risk of damage to the components. Finite-element modelling studies indicate the effectiveness of the compliant structure in facilitating peg removal.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Multidisciplinary Sciences
Mairi Kerin, Natalia Hartono, D. T. Pham
Summary: Remanufacturing is an important aspect of the circular economy, but its connection with Industry 4.0 has been overlooked. The concept of digital twin, which represents a combination of Industry 4.0 technologies and methodologies, has been recognized as a facilitator for extending product lifecycles. This article presents a digital twin model that uses data from different stages of a product's life cycle to optimize remanufacturing planning, with the integration of a neural network for remaining useful life prediction and the Bees Algorithm for decision making. The model is validated through a real case study, showing that intelligent tools within a digital twin can enhance decision-making when provided with visibility of the product's current status and reliable remanufacturing process information.
SCIENTIFIC REPORTS
(2023)
Article
Engineering, Chemical
Nikolina Kovacev, Omid Doustdar, Sheng Li, Athanasios Tsolakis, Jose Martin Herreros, Khamis Essa
Summary: This study proposes 3D-printed diamond-based lattice substrates as catalytic converters to improve vehicle cold-start emissions. The study compares the influence of these structures on light-off behavior compared to conventional designs and examines the benefits of H-2 addition on catalytic efficiency. The results show significant improvement in light-off temperatures for CO, THC and NO in the 3D-printed lattice structures, and H-2 presence further enhances their low-temperature activity.
CHEMICAL ENGINEERING SCIENCE
(2023)
Article
Chemistry, Physical
Rashid Khan, Sabbah Ataya, Islam Elgammal, Khamis Essa
Summary: This study improved the productivity and reduced power consumption in rebar steel production by modifying and optimizing the slitting process. By reviewing and modifying the slitting passes, better rolling stability and power reduction were achieved. Finite element simulations were used to validate the modeling parameters and compare the power consumption of single and double barreled strips.
Article
Polymer Science
Alessandro Abena, Sein Leung Soo, Sabbah Ataya, Hany Hassanin, Mahmoud Ahmed El-Sayed, Mahmoud Ahmadein, Naser A. Alsaleh, Mohamed M. Z. Ahmed, Khamis Essa
Summary: This study conducted comprehensive experimental research using the design of experiments and analysis of variance (ANOVA) to investigate the effects of machining process parameters on chip formation mechanisms, machining forces, workpiece surface integrity, and damage in cutting unidirectional CFRP. The study identified the impact of chip formation mechanisms on fibre orientation and tool cutting angle, affecting fibre bounceback and damage depth. An analytical model based on response surface analysis was developed to predict machining forces, damage, surface roughness, and bounceback. ANOVA results indicated that fibre orientation had the most significant influence on CFRP machining. Optimized cutting parameters were determined to improve surface quality and reduce forces for different fibre angles.
Article
Polymer Science
Abdullah H. Mohammed, Nikolina Kovacev, Amr Elshaer, Ammar A. Melaibari, Javed Iqbal, Hany Hassanin, Khamis Essa, Adnan Memic
Summary: Fused Deposition Modelling (FDM) 3D printers have gained popularity in the pharmaceutical and biomedical industries. This study developed a new biomaterial filament, PLA/CPO, using wet solution mixing and extrusion. The filaments were characterized and the findings showed changes in viscosity, microstructure, and mechanical properties with varying CPO content. The PLA/CPO filament with 6% CPO showed acceptable surface morphology and strength, making it suitable for 3D printing applications such as bone scaffolds.
Article
Chemistry, Analytical
Quan Liu, Wupeng Deng, Duc Truong Pham, Jiwei Hu, Yongjing Wang, Zude Zhou
Summary: To make remanufacturing more economically attractive, the development of automatic disassembly and automated visual detection methods is necessary. This paper proposes a two-stage detection framework for detecting structurally damaged screws, using a linear regression model of reflection features that can handle uneven illumination conditions. The first stage extracts screws using reflection features and regression model, while the second stage filters out false areas using texture features. The detection framework is implemented on a robotic platform for disassembling electric vehicle batteries, enabling automatic screw removal in complex disassembly tasks and providing new ideas for future research through the use of reflection features and data learning.
Article
Computer Science, Interdisciplinary Applications
Natalia Hartono, F. Javier Ramirez, D. T. Pham
Summary: This paper presents a multiobjective decision-making approach for robotic disassembly, with the goals of enhancing economic performance, reducing energy consumption, and mitigating environmental impact. Real-use cases are used as demonstrators, and different optimization algorithms are adopted to solve the multiobjective problem.
COMPUTERS & INDUSTRIAL ENGINEERING
(2023)
Article
Multidisciplinary Sciences
Feiying Lan, Marco Castellani, Duc Truong Pham, Yongjing Wang
Summary: This paper investigates the correctness of using two-dimensional models for analyzing the assembly and disassembly operations of the cylindrical peg-hole system. The analysis shows that while geometrical equivalence can be proven, kinematic equivalence is generally not verified. The results indicate that a two-dimensional model may give wrong predictions on jamming and reduce the possibility of peg-hole wedging.
ROYAL SOCIETY OPEN SCIENCE
(2023)
Article
Engineering, Manufacturing
Mohammad Almadani, Ahmet Guner, Hany Hassanin, Khamis Essa
Summary: This study introduces a novel contactless single-point incremental forming (CSPIF) technique using hot compressed air as a deformation tool. The technique allows for precise shaping and minimal springback of the material. However, minor deviations from the designed profile, sheet thinning, and material buildup were observed.
JOURNAL OF MANUFACTURING AND MATERIALS PROCESSING
(2023)
Article
Automation & Control Systems
Mohammad Almadani, Ahmet Guner, Hany Hassanin, Michele De Lisi, Khamis Essa
Summary: The demand for small-batch manufacturing processes has increased due to the need for personalized and customized products. Single point incremental forming (SPIF) is a time-efficient method that offers increased material formability. This study utilizes a non-conventional contactless tool to form polycarbonate sheets and models the influence of the tool using finite element modelling. The research provides a working model that accurately predicts the performance of this contactless incremental forming process of polymers.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Materials Science, Multidisciplinary
Prveen Bidare, Amaia Jimenez, Sherif M. Abdelkhalek, Iman Khaled, Ali Hassan, Ramy Abdallah, Khamis Essa
Summary: This paper investigates the issue of heat accumulation and shape distortions in additive manufacturing. It analyzes the feasibility of interlayer post-processing methods, such as interlayer machining and laser remelting, to improve interlayer bonding and process performance. The results show that machining post-processing reduces deformation, while laser remelting achieves the best results in reducing porosity. Hardness tests also demonstrate an increase in hardness along the build direction. Overall, the hybrid additive manufacturing approach has beneficial effects on the generated parts.
MATERIALS TODAY COMMUNICATIONS
(2023)
