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AI Applications in Sheet Metal Forming Topics in Mining, Metallurgy and Materials Engineering 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 should present scientific solutions for technological problems. The three focus areas have a vertically lined multidisciplinarity, starting from mineral assets, their extraction and processing, their transformation into materials useful for the society, and their interaction with the environment. More information about this series at http://www.springer.com/series/11054 Shailendra Kumar • Hussein M.A. Hussein Editors AI Applications in Sheet Metal Forming 123 Editors Shailendra Kumar Hussein M.A. Hussein Mechanical Engineering Department Mechanical Engineering Department S.V. National Institute of Technology Helwan University Surat, Gujarat Cairo India Egypt ISSN 2364-3293 ISSN 2364-3307 (electronic) Topics in Mining, Metallurgy and Materials Engineering ISBN 978-981-10-2250-0 ISBN 978-981-10-2251-7 (eBook) DOI 10.1007/978-981-10-2251-7 Library of Congress Control Number: 2016951696 © Springer Science+Business Media Singapore 2017 This work is subject to copyright. All rights are reserved by the Publisher, whether the whole or part 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 or information storage and retrieval, electronic adaptation, computer software, or by similar or dissimilar methodology now known or hereafter developed. The use of general descriptive names, registered names, trademarks, service marks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. 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 authors or the editors give a warranty, express or implied, with respect to the material contained herein or for any errors or omissions that may have been made. Printed on acid-free paper This Springer imprint is published by Springer Nature The registered company is Springer Nature Singapore Pte Ltd. The registered company address is: 152 Beach Road, #22-06/08 Gateway East, Singapore 189721, 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 years and being a founder member of the Advances in Materials and Processing 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), use of various techniques in sheet metal forming was started in the 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, and experience-based processing to fully automated processing of 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 of AI applications in sheet metal forming. As the research works of the editors have been presented and published in many AMPT conferences and reputed journals, they are admirably qualified to bring such a book. Authors of chapters of this book are very competent in the domain of material processing. The book is not overly research or academic oriented, but considers the industrial applications of the work. Applications of various AI techniques have been discussed in almost all activities of sheet metal processing including feature extraction, manufacturability assessment, process planning, die design, die modeling, and prediction of die life. Examples of 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 The innumerable tasks associated with sheet metal forming such as process planning 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 changing demand of high-quality consumer products economically. 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. Recent advances in the field of Artificial Intelligence (AI) have given rise 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 perform tasks that require intelligence. Nowadays, number of tools and techniques of AI are widely used in the various sectors of 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. The idea to write this book germinated when we had a detailed discussion during AMPT conference held in December 2014 at Dubai. Our attempts to comprehensively search for availability of book containing research outcomes in the area of sheet metal forming with AI applications prompted us for initiating this task in the absence of any such compiled edition. Since the book was planned to include many topics related to the domain, it would not have been possible for both of us to write all of them on our own. Therefore, it was felt appropriate to approach researchers working in this area to contribute for the dif- ferent chapters of this book. Professor A.Y.C. Nee, who is one of the pioneers in the 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 bending dies. All chapters of this book present results of dedicated research efforts 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 chapters of this book. We would also like to acknowledge the efforts of Ms. 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 .........................................
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