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Efficiency of optimization algorithms on the adjustment of process parameters for geometric accuracy enhancement of denture plate in single point incremental sheet forming

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Abstract

Single point incremental forming is a sheet metal forming technique with great potential for use in prototyping and custom manufacture. Although this technology has undergone considerable development in recent years, it still suffers from low geometrical accuracy in terms of its application in the industry. Therefore, solutions for errors reduction or compensation are required to improve the process. In this paper, an optimization procedure of the geometric precision, based on genetic algorithm, global optimum determination by linking and interchanging kindred evaluators solver and newly developed algorithm called grasshopper optimization algorithm, is tested and doubly validated numerically and experimentally. The denture plate part simultaneously simulated and manufactured shows how it is possible to obtain sound component with reduced geometric errors such as springback, bending and pillow effect errors by properly chosen optimal process parameters. The results indicated that the reduction in the shape defects between the obtained geometry and the target model generated by computer-aided design can be achieved through coupling of numerical simulations and optimization techniques.

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Abbreviations

ISF:

Incremental sheet forming

SPIF:

Single point incremental forming

CAD/CAM:

Computer-aided design/computer-aided manufacturing

DICOM:

Digital image and communications in medicine

CT:

Computerized tomography

PCL:

Polycaprolactone

MARS:

Multivariate adaptive regression splines

MPC:

Model predictive control

RSM:

Response surface methodology

FE:

Finite element

DoE:

Design of the experiments

BBD:

Box–Behnken design of experiments

ANOVA:

Analysis of variance

GAs:

Genetic algorithms

MaxGen:

Maximum number of generations

GODLIKE:

Global optimum determination by linking and interchanging kindred evaluators

POF:

Pareto optimal frontier

GA:

Genetic algorithm

DE:

Differential evolution

PSO:

Particle swarm optimization

ASA:

Adaptive simulated annealing

GOA:

Grasshopper optimization algorithm

SOOP:

Single-objective optimization problems

MOOP:

Multi-objective optimization problems

MOGA:

Multi-objective genetic algorithm

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Acknowledgements

The authors would like to thank the Faculty of Dental Medicine of Monastir, Tunisia for providing the original denture plate prosthesis and the German Research Foundation DFG for the kind support within the Cluster of Excellence “Integrative Production Technology for High-Wage Countries.” Furthermore, the authors thank the Institute of Metal Forming of RWTH Aachen University for their support in the performance and evaluation of the incremental sheet forming experiments.

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  1. Laboratory of Mechanical Engineering (LGM), National Engineering School of Monastir (ENIM), University of Monastir, Av. Ibn El Jazzar, 5000, Monastir, Tunisia

    Manel Sbayti, Riadh Bahloul & Hedi Belhadjsalah

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  1. Manel Sbayti
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Sbayti, M., Bahloul, R. & Belhadjsalah, H. Efficiency of optimization algorithms on the adjustment of process parameters for geometric accuracy enhancement of denture plate in single point incremental sheet forming. Neural Comput & Applic 32, 8829–8846 (2020). https://doi.org/10.1007/s00521-019-04354-y

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