Experimental and Numerical Investigation of Sheet Metal Forming Using Multi-point Forming Process

Multi-Point forming process is a flexible technique for manufacturing of various sheet metal parts. In this paper, Multi-Point forming technique is studied using FE simulation and experiments. In order to estimate proper design parameters, the forming process was initially simulated dynamically, and then the Multi-Point forming die set was built for conducting experimental tests. By considering the widespread usage of aluminum alloys in the field of aerospace, the AA2024 aluminum alloy is used in this research and forming of sheet parts under various forming conditions is examined. The failure modes are predicted and the effect of process parameters such as pin diameter and thickness of elastic cushion on the geometry accuracy and thickness distribution of formed parts are investigated.The results obtained show that this process can be used as an effective and economic method for producing small batch production in different industrial sectors particularly aerospace industry. By proper adjustment of process parameters, the production of parts with different geometry will be possible just by using one same die set.