Abstract
Flexibility is crucial in forming processes as it allows the production of different product shapes without changing equipment or tooling. Single-point incremental forming (SPIF) provides this flexibility, but often results in excessive sheet metal thinning. To solve this problem, a pre-forming phase can be introduced to ensure a more uniform thickness distribution. This study represents advances in this field by developing a generalised approach that uses a multilayer perceptron artificial neural network (MLP ANN) to predict thinning results from the input parameters and employs a genetic algorithm (GA) to optimise these parameters. This study specifically addresses advanced high-strength steels (AHSSs) and provides insights into their formability and the optimisation of the forming process. The results demonstrate the effectiveness of the proposed method in minimising sheet metal thinning and represent a significant advance in flexible forming technologies applicable to a wide range of materials and industrial applications.