Polymer Shaped Punches Produces with Fused Filament Fabrication to Improve Cup Accuracy in Sheet Metal Forming
Bibliographic record
Abstract
Rapid tooling has become an effective solution for reducing time and costs in tool production. In sheet metal forming, polymer tools produced via additive manufacturing offer performance comparable to traditional tools. However, a key challenge in this area is compensating for the radial expansion of polymer tools during the forming process, which leads to reduced accuracy in the produced parts and limits the achievable forming depth. To address this issue, the authors of this study proposed a novel punch design aimed at containing radial expansion, thereby enabling greater drawing depth and improved part accuracy. Different punch geometries were designed with a re-entrant angle varying between 150° and 180°. Numerical simulations were conducted to evaluate the optimal geometry, identifying the 160° angle as the best option to compensate for radial expansion and reduce punch load. Experimental tests were then performed to verify the numerical results, demonstrating the potential of this new design producing cups with higher drawing depth and best radial accuracy.
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How this classification was reachedexpand
Full frame distilled prediction
Teacher imitationNot calibrated prevalence, not ground truth. Human validation pending. Learned from the 10,348 direct Codex labels and 10,348 direct Gemma labels. Candidate is the union of thresholded teacher heads; consensus is their intersection. These outputs are machine_predicted_unvalidated and are not human labels or direct frontier model labels.
Codex and Gemma teacher scores by category
| Category | Codex | Gemma |
|---|---|---|
| Metaresearch | 0.003 | 0.001 |
| Meta-epidemiology (narrow) | 0.000 | 0.000 |
| Meta-epidemiology (broad) | 0.000 | 0.000 |
| Bibliometrics | 0.002 | 0.002 |
| Science and technology studies | 0.000 | 0.000 |
| Scholarly communication | 0.000 | 0.001 |
| Open science | 0.001 | 0.000 |
| Research integrity | 0.000 | 0.001 |
| Insufficient payload (model declined to judge) | 0.000 | 0.000 |
Machine scores (provisional)
The two teacher heads of the student model, read on this work. A score orders the frame for review; it never asserts a category, and the validation status ships verbatim with every row.
Baseline scores from an immature model (maturity gate not passed, 7 training rounds). Scores rank; they never assert a category.
score_only:v0-immature-baseline · verbatim from the scoring run: score_only means the number may rank works, and no category label ships from itClassification
machine, unvalidatedMachine predicted; a candidate call from one teacher head, not a consensus.
How this classification was reached, model by model and score by score, is at the end of the page under "How this classification was reached".