Development of a Hybrid Fuzzy AHP–CoCoSo-Based Multiscale Ranking Model for Incremental Sheet Metal Forming of Conical Micro-Cups

Abstract This study aims to optimize the incremental sheet metal forming process for conical microcups, addressing the challenges of ensuring high-quality production and timely delivery. The research introduces a hybrid Fuzzy AHP + Fuzzy CoCoSo model for sustainable optimization to meet these demands. The optimization approach integrates the Fuzzy Analytical Hierarchical Process (Fuzzy AHP) with the Fuzzy Combined Compromise Solution (Fuzzy CoCoSo). A structured experimental investigation was carried out using Response Surface Methodology (RSM), applying a randomized D-optimal design comprising 15 tailored trials. The statistical framework adopted a reduced quadratic model to interpret the interaction effects. The analysis prioritized key performance indicators such as dimensional precision, quality metrics, microstructural characteristics, and stored energy variations. Statistical robustness was ensured through Analysis of Variance (ANOVA) and sensitivity studies, offering insights into parameter influence. Among the tested configurations, Among the tested configurations, A9 achieved the most favorable outcomes, while A5 contributed least to process optimization. Validation trials confirmed the reliability of the proposed hybrid framework in improving formability, mechanical integrity, and process efficiency. The model demonstrated strong robustness and predictive accuracy across performance metrics. The study focuses on conical microcups and may require adaptation for other product geometries and manufacturing processes. The limited number of experimental runs (15) may affect the generalizability of the results. The proposed hybrid model offers a reliable framework for manufacturing managers to optimize production processes, enhancing product quality and delivery timeliness. The approach can be applied to various precision-driven manufacturing contexts. This research presents a novel integration of Fuzzy AHP and Fuzzy CoCoSo for sustainable optimization in incremental sheet metal forming. It contributes to both academic literature and practical applications in production management by improving decision-making for quality and efficiency.