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

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.