The Influence of Process Parameters on Thickness Distribution in Multipoint Forming Process Using Finite Element Analysis

Abstract

Multipoint forming (MPF) process is a flexible manufacture technology, and this technology was inspired from the idea that the whole die is separated into small punches called pins with different height. Several different products can be made without changing tool is saved precious production time. Also the manufacturing of very expensive rigid die is reduced. The most important aspects of using such types of equipment's is the flexibility of the tooling.This work aims to design and implement a developed multi points die with a new concept that depends on spring’s properties to generate the necessary force to deform the sheet metal without needed to set the pins in a single way. In experimental phase, three variables were adopted in multipoints forming process, which are: type of blank holder, elastic cushion thickness, and forming speed with three levels for each variable, and then investigate the effect of the variables on the thickness distribution of the produced models. These variables were adopted to deform a hemispherical shape of brass (Cu Zn 65-35).In simulation phase, ANSYSE software has been used to perform the simulation of the forming process as well as to predict the results of thickness distribution, and the results obtained from the software are close to those of the experiments and the difference between the results are not exceed 6%.