Multi-point forming using mesh-type elastic cushion: modelling and experimentation

A. Tolipov, A. Elghawail, M. Abosaf, D. Pham, H. Hassanin, K. Essa

Research output: Contribution to journalArticlepeer-review

4 Citations (Scopus)
240 Downloads (Pure)


There is a growing demand for flexible manufacturing techniques that meet the rapid changes in production technology, processes and innovations. Multi-point forming (MPF) is a flexible sheet metal forming technique where a reconfigurable die can be readily changed to produce various shapes. Parts produced using MFP suffers from geometrical defects such as wrinkling, dimpling and thickness variations. In this paper, a multi-point forming process using a novel mesh-type elastic cushion was proposed in order to improve the quality of the deformed sheet and to minimize the developed defects. Finite element modelling (FEM) and design of experiments (DoE) were used to study the influence of the mesh-type elastic cushion parameters such as the type and the size of the mesh, and the thickness of the cushion on the wrinkling, deviation, and thickness variation of the deformed sheet. The results showed that using elastic cushion with square meshes of a size of 3.5 mm and a thickness of 3 mm reduced the wrinkling from 3.18 mm to 1.98 mm while the thickness variation improved from 98 µm to 19 µm. Finally, the deviation from target shape reduced from 1.7848 mm to 0.0358 mm.
Original languageEnglish
Pages (from-to)2079–2090
Number of pages12
JournalThe International Journal of Advanced Manufacturing Technology
Issue number5-8
Early online date16 Apr 2019
Publication statusPublished - 1 Aug 2019


  • Multi-point forming
  • Mesh-Type Elastic Cushion
  • finite element modelling
  • Design of Experiment

ASJC Scopus subject areas

  • Software
  • Mechanical Engineering
  • Control and Systems Engineering
  • Industrial and Manufacturing Engineering
  • Computer Science Applications


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