Topics in Mining, Metallurgy and Materials Engineering Series Editor: Carlos P. Bergmann Shailendra Kumar Hussein M.A. Hussein Editors AI Applications in Sheet Metal Forming Topics in Mining, Metallurgy and Materials Engineering Series editor Carlos P. Bergmann, Porto Alegre, Brazil “Topics in Mining, Metallurgy and Materials Engineering” welcomes manuscripts in these three main focus areas: Extractive Metallurgy/Mineral Technology; Manufacturing Processes, and Materials Science and Technology. Manuscripts shouldpresentscientificsolutionsfortechnologicalproblems.Thethreefocusareas have a vertically lined multidisciplinarity, starting from mineral assets, their extractionandprocessing,theirtransformationintomaterialsusefulforthesociety, and their interaction with the environment. More information about this series at http://www.springer.com/series/11054 Shailendra Kumar Hussein M.A. Hussein (cid:129) Editors AI Applications in Sheet Metal Forming 123 Editors ShailendraKumar HusseinM.A. Hussein MechanicalEngineering Department MechanicalEngineering Department S.V. National Institute of Technology HelwanUniversity Surat, Gujarat Cairo India Egypt ISSN 2364-3293 ISSN 2364-3307 (electronic) Topicsin Mining,Metallurgy andMaterials Engineering ISBN978-981-10-2250-0 ISBN978-981-10-2251-7 (eBook) DOI 10.1007/978-981-10-2251-7 LibraryofCongressControlNumber:2016951696 ©SpringerScience+BusinessMediaSingapore2017 Thisworkissubjecttocopyright.AllrightsarereservedbythePublisher,whetherthewholeorpart of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission orinformationstorageandretrieval,electronicadaptation,computersoftware,orbysimilarordissimilar methodologynowknownorhereafterdeveloped. The use of general descriptive names, registered names, trademarks, service marks, etc. in this publicationdoesnotimply,evenintheabsenceofaspecificstatement,thatsuchnamesareexemptfrom therelevantprotectivelawsandregulationsandthereforefreeforgeneraluse. The publisher, the authors and the editors are safe to assume that the advice and information in this book are believed to be true and accurate at the date of publication. Neither the publisher nor the authorsortheeditorsgiveawarranty,expressorimplied,withrespecttothematerialcontainedhereinor foranyerrorsoromissionsthatmayhavebeenmade. Printedonacid-freepaper ThisSpringerimprintispublishedbySpringerNature TheregisteredcompanyisSpringerNatureSingaporePteLtd. Theregisteredcompanyaddressis:152BeachRoad,#22-06/08GatewayEast,Singapore189721,Singapore Foreword I am pleased to write a foreword to this book on AI Applications in Sheet Metal Forming. Having associated with “Journal of Materials Processing Technology” (previously titled “Journal of Mechanical Working Technology”) for around 12 yearsandbeingafoundermemberoftheAdvancesinMaterialsandProcessing Technologies (AMPT) conference series, I have seen many dramatic changes that have occurred in the materials processing domain especially in sheet metal pro- cessing. Like many other manufacturing processes, the technology of sheet metal forming has transformed from experience-based craft work to the semi-/fully automated computer-aided processing. Long gone are the days when the process planning and design of tooling for sheet metal work was considered an art rather than science. With the advancement in the domains of computer and artificial intelligence(AI),useofvarioustechniquesinsheetmetalformingwasstartedinthe late 1980s and early 1990s. Nowadays, researchers worldwide are engaged in automation of the tedious and time-consuming tasks of sheet metal forming including product design, process planning and die design by using various AI techniques. However, considerable efforts are still required for actual implemen- tation of this research work in sheet metal industries to convert tedious, time-consuming,andexperience-basedprocessingtofullyautomatedprocessingof sheet metal. It is with great pleasure therefore to see this new book edited by Shailendra Kumar and Hussein M.A. Hussein focusing on the latest developments in the area ofAIapplicationsinsheetmetalforming.Astheresearchworksoftheeditorshave been presented and published in many AMPT conferences and reputed journals, theyareadmirablyqualifiedtobringsuchabook.Authorsofchaptersofthisbook are very competent in the domain of material processing. The book is not overly researchoracademicoriented,butconsiderstheindustrialapplicationsofthework. ApplicationsofvariousAItechniqueshavebeendiscussedinalmostallactivitiesof sheet metal processing including feature extraction, manufacturability assessment, processplanning,diedesign,diemodeling,andpredictionofdielife.Examplesof industrial parts have been taken to demonstrate the actual applications of the AI v vi Foreword techniques and systems in sheet metal industries. I am sure that this book will be very much useful not only to the researchers and academicians but also a very useful reference for industrial practitioners. I congratulate the editors on having produced this splendid new book and I convey my best wishes for their success. Prof. M.S.J. Hashmi, Ph.D., DSc. CEng, FIEI, FIMechE Editor-in-Chief, Reference Module in Materials Science and Materials Engineering (Elsevier), Emeritus Professor School of Mechanical & Manufacturing Engineering Dublin City University Dublin 9, Ireland Preface Theinnumerabletasksassociatedwithsheetmetalformingsuchasprocessplanning and tool design are complex, time-consuming, tedious, and highly skill intensive. However, there is scarcity of domain experts worldwide to deal with the fast changingdemandofhigh-qualityconsumerproductseconomically.Moreover,sheet metal industries face challenges of frequent mobility of domain experts without adequate dissemination of knowledge to the new generation of industry profes- sionals. This can be handled effectively by adopting automation in sheet metal industries.RecentadvancesinthefieldofArtificialIntelligence(AI)havegivenrise to the possibility of developing intelligent systems for automation of various activities of sheet metal forming. AI aims at building systems impregnated with some intelligence in their operation or behavior and investigate the way humans performtasksthatrequireintelligence.Nowadays,numberoftoolsandtechniquesof AI are widely usedin thevarioussectorsof manufacturing. The primary goal of this book is to incorporate, as much as possible, the state-of-the art development in the applications of AI in the domain of sheet metal forming.Theideatowritethisbookgerminatedwhenwehadadetaileddiscussion during AMPT conference held in December 2014 at Dubai. Our attempts to comprehensively search for availability of book containing researchoutcomesintheareaofsheetmetalformingwithAIapplicationsprompted us for initiating this task in the absence of any such compiled edition. Since the book was planned toinclude many topics related to the domain, it would not have been possible for both ofus towriteall of them on ourown. Therefore, it was felt appropriate to approach researchers working in this area to contribute for the dif- ferentchaptersofthisbook.ProfessorA.Y.C.Nee,whoisoneofthepioneersinthe domain of material processing, gracefully accepted our invitation to write the introductory chapter for this book. The book is focused on various applications of different AI tools/techniques in sheet metal forming including feature extraction, manufacturability assessment, process planning, selection of die components, and die modeling. It covers the vii viii Preface design of various types of dies including blanking, deep drawing, compound, and bendingdies. All chapters ofthis bookpresentresultsofdedicatedresearchefforts of authors for years. The book not only highlights the latest research status in the domain but also identifies future scope of work for young graduates. There is no doubt that sheet metal industries will also be benefitted by the research work reported in various chapters of this book. During the period of preparing manuscript for the book, we have received excellent support from our Ph.D. students and project research fellows especially Mr. Rahul Jagtap, Vikas Sisodia. Ajit Dhanawade, and Ajay Trivedi. We would also like to deeply acknowledge the valuable contributions by authors of various chaptersof this book.We would also like to acknowledge theefforts ofMs. Swati Meherishi and her team at Springer for their support in timely publication of this book. At the end, we would like to dedicate the book to all domain experts and researchers who are directly or indirectly engaged in manufacturing of sheet metal parts. Surat, India Shailendra Kumar Cairo, Egypt Hussein M.A. Hussein Contents An Overview of Applications of Artificial Intelligence (AI) in Sheet Metal Work.... .... ..... .... .... .... .... .... ..... .... 1 A.Y.C. Nee Generic Classification and Representation of Shape Features in Sheet-Metal Parts.... .... ..... .... .... .... .... .... ..... .... 15 Ravi Kumar Gupta, Yicha Zhang, Alain Bernard and Balan Gurumoorthy Feature Extraction and Manufacturability Assessment of Sheet Metal Parts.... .... ..... .... .... .... .... .... ..... .... 41 Shailendra Kumar, Rajender Singh, Deepak Panghal, Sachin Salunkhe and Hussein M.A. Hussein Knowledge-Based System for Design of Blanking Dies . .... ..... .... 67 Hussein M.A. Hussein, Azza F. Barakat, Wang Fengyin and Shailendra Kumar Knowledge-Based System for Design of Deep Drawing Die for Axisymmetric Parts .. ..... .... .... .... .... .... ..... .... 93 Vishal Naranje and Shailendra Kumar An Integrated Approach for Optimized Process Planning of Multistage Deep Drawing.. ..... .... .... .... .... .... ..... .... 121 Ragab K. Abdel-Magied, Tamer F. Abdelmaguid, Mostafa Shazly and Abdalla S. Wifi Knowledge-Based System for Design of Deep Drawing Die for Elliptical Shape Parts. ..... .... .... .... .... .... ..... .... 161 D.H. Park An Expert System for Automatic Design of Compound Dies. ..... .... 183 Sachin Salunkhe, Shailendra Kumar and Hussein M.A. Hussein ix