Multi-stage incremental sheet forming system and method

Abstract

A multi-stage incremental sheet forming system includes a forming tool and at least one control unit in communication with the forming tool. The at least one control unit is configured to determine a convex hull of a target structure to be formed by the forming tool. The at least one control unit is further configured to operate the forming tool with respect to an initial structure according to a first tool path to form an intermediate structure having a shape based on the convex hull of the target structure. The at least one control unit is further configured to operate the forming tool with respect to the intermediate structure according to a second tool path to form one or more inward features into the intermediate structure to form the target structure.

Description

Technical Field

[0001] The embodiments of this disclosure generally relate to multi-stage incremental sheet forming systems and methods. Background Technology

[0002] Some structures are formed by incremental sheet forming. In particular, incremental sheet forming provides a method for forming thin structures from metal. The forming tool typically includes a smooth, blunt operating head that is pressed or otherwise positioned against the surface of the sheet metal suspended in a jig, fixture, or similar fixture to provide an improved three-dimensional shape.

[0003] In incremental sheet forming, forming tools (e.g., forming styluses) traverse the toolpath to incrementally deform the blank sheet metal. The toolpath is typically generated by stacking horizontal cross-sections of the geometry of the part to be formed; this is known as the Z-layer toolpath.

[0004] Incremental sheet forming processes are known to be sensitive to local wall inclination angles. Typically, structures with wall angles steeper than 60 degrees from the horizontal plane are generally not viable candidates for incremental sheet forming. At 60 degrees or greater, the sheet metal formed by incremental sheet forming typically thins to about half its original thickness. Attempting to form such structures via incremental sheet forming has been found to carry the risk of tearing the steep walls of the material.

[0005] In general, applying single-stage incremental sheet forming to parts with features such as cavities, recesses, and similar characteristics formed on steep walls (e.g., walls formed at angles of at least 60 degrees) is often unsuccessful. Using Z-layer toolpaths, steep walls can cause excessive thinning during forming, leading to (or at least risking) tearing of the material sheet. Structures with wall angles of 60 degrees or greater are generally unsuitable for incremental sheet forming. Summary of the Invention

[0006] There is a need for systems and methods for forming structures with steep walls (e.g., walls at angles of 60 degrees or greater) using incremental sheet forming. Furthermore, there is a need for incremental sheet forming systems and methods that prevent structural materials from being easily damaged (e.g., torn) at steep angles (e.g., 60 degrees or greater).

[0007] In view of those needs, certain embodiments of this disclosure provide a multi-stage incremental sheet forming system including a forming tool and at least one control unit in communication with the forming tool. The at least one control unit is configured to determine a convex hull of a target structure formed by the forming tool. The at least one control unit is configured to operate the forming tool relative to an initial structure according to a first toolpath to form an intermediate structure having a shape based on the convex hull of the target structure. The at least one control unit is configured to operate the forming tool relative to the intermediate structure according to a second toolpath to form one or more inward features into the intermediate structure to form the target structure, wherein the second toolpath differs from the first toolpath.

[0008] In at least one embodiment, the at least one control unit includes: a tool path generation control unit configured to determine at least one tool path; a tool path generation control unit configured to determine the convex hull of a target structure; and a forming control unit configured to operate a forming tool.

[0009] In at least one embodiment, the at least one control unit includes: a tool path generation control unit configured to determine the convex hull of the target structure based on a minimum convex set containing all points of the target structure.

[0010] In at least one embodiment, the structural database communicates with the at least one control unit. The structural database stores target data, including information relating to the geometric representation of the target structure, such as the size of the target structure, the shape of the target structure, one or more inward features of the target structure, and manufacturing data including tool shape, tool size, and tool feed rate.

[0011] In at least one embodiment, the at least one control unit includes: a tool path generation control unit, which includes a convex hull determination module that analyzes target data related to the target structure and determines the convex hull of the target structure based on the target data.

[0012] In at least one embodiment, the at least one control unit includes a tool path generation control unit, which includes a convex hull tool path generation module that determines a first tool path based on a determined convex hull. A forming control unit operates a forming tool relative to an initial structure according to the first tool path to form an intermediate structure having a shape of a convex hull based on a target structure. For example, the first tool path is a Z-layer tool path.

[0013] In at least one embodiment, the at least one control unit includes a tool path generation control unit comprising a target structure tool path generation module configured to operate or output, or both operate and output, instructions for operating a forming tool relative to an intermediate structure according to a second tool path, to form one or more inward features into the intermediate structure to form the target structure. As an example, the second tool path is a lace tool path.

[0014] In at least one embodiment, the one or more inward features include one or more of at least one recess, at least one cavity, at least one notch, at least one channel, at least one depression, at least one groove, at least one indentation, at least one hole, at least one indentation, or at least one hole.

[0015] In at least one embodiment, the target structure includes at least one wall disposed at an angle of at least 60 degrees relative to a horizontal plane. In at least one embodiment, the intermediate structure does not have one or more inward features.

[0016] Certain embodiments of this disclosure provide a multi-stage incremental sheet forming method comprising: determining a convex hull of a target structure to be formed by a forming tool via at least one control unit; operating the forming tool relative to an initial structure via the at least one control unit according to a first tool path to form an intermediate structure having a shape based on the convex hull of the target structure; and operating the forming tool relative to the intermediate structure via the at least one control unit according to a second tool path to form one or more inward features into the intermediate structure to form the target structure, wherein the second tool path is different from the first tool path. Attached Figure Description

[0017] Figure 1 A schematic block diagram of a multi-stage incremental sheet forming system according to an embodiment of the present disclosure is shown.

[0018] Figure 2 A flowchart of a multi-stage incremental sheet forming system according to an embodiment of the present disclosure is shown.

[0019] Figure 3 A perspective view of the target structure according to an embodiment of the present disclosure is shown.

[0020] Figure 4 An embodiment of the present disclosure is shown with a based Figure 3 A three-dimensional view of the intermediate structure of the convex hull shape of the target structure.

[0021] Figure 5 It shows the operation of a forming tool according to a first toolpath to form Figure 4 A three-dimensional view of the intermediate structure.

[0022] Figure 6 This illustrates the operation of a forming tool according to a second toolpath to form... Figure 3 A three-dimensional view of the target structure.

[0023] Figure 7 A perspective view of the target structure according to an embodiment of the present disclosure is shown.

[0024] Figure 8 The embodiment of the present disclosure is shown as follows: Figure 7 A three-dimensional view of the intermediate structure of the convex hull of the target structure.

[0025] Figure 9 It shows the operation of a forming tool according to a first toolpath to form Figure 8 A three-dimensional view of the target structure.

[0026] Figure 10 This illustrates the operation of a forming tool according to a second toolpath to form... Figure 7 A three-dimensional view of the target structure.

[0027] Figure 11 A perspective view of the target structure according to an embodiment of the present disclosure is shown.

[0028] Figure 12 The embodiment of the present disclosure is shown as follows: Figure 11 A three-dimensional view of the intermediate structure of the convex hull of the target structure.

[0029] Figure 13 A perspective view of the target structure according to an embodiment of the present disclosure is shown.

[0030] Figure 14 The formation according to an embodiment of the present disclosure is shown as follows. Figure 13 A three-dimensional view of the intermediate structure of the convex hull of the target structure. Detailed Implementation

[0031] The foregoing overview and the following detailed description of certain embodiments will be better understood when read in conjunction with the accompanying drawings. As used herein, elements or steps listed in the singular and preceded by the word "a" or "one" should be understood to not necessarily exclude multiple elements or steps. Furthermore, references to "an embodiment" are not intended to exclude the existence of other embodiments that also incorporate the listed features. Additionally, unless explicitly stated to the contrary, embodiments that "comprise" or "have" one or more elements having a particular condition may include additional elements that do not have that condition.

[0032] Certain embodiments of this disclosure provide a multi-stage incremental sheet forming system and method. The multi-stage incremental sheet forming system and method include a first forming operation to form an intermediate structure having a shape with a convex hull based on a target structure. For example, the intermediate structure may be formed as a convex hull of the target structure. The intermediate structure is formed by operating a forming tool according to a first tool path (e.g., via a predetermined tool path having a start and an end point). After forming the intermediate structure with a shape with a convex hull based on the target structure, the forming tool is operated according to a second tool path different from the first tool path (e.g., via a predetermined tool path having a start and an end point) to form inward features in the intermediate structure (e.g., the convex hull of the target structure) to form the target structure.

[0033] To avoid the potential risk of damage due to steep walls (e.g., walls at an angle of 60 degrees or greater relative to a horizontal plane), embodiments of this disclosure form the structure in two stages. In at least one embodiment, the first stage includes a forming tool traversing along a Z-layer tool path to form a bulge of the target structure. The second stage includes a forming tool traversing along a lace tool path to form the target structure, which may include one or more inward features. Thus, embodiments of this disclosure enable the formation of various structures with steep, angled walls via an incremental sheet forming process.

[0034] Figure 1 A schematic block diagram of a multi-stage incremental sheet forming system 100 according to embodiments of the present disclosure is shown. In at least one embodiment, the incremental sheet forming system 100 includes a tool path generation control unit 102, such as communicating with a structure database 104 via one or more wired or wireless connections. The tool path generation control unit 102 may also communicate with a user interface 106, such as via one or more wired or wireless connections. The tool path generation control unit 102 may be co-located with one or both of the structure database 104 and / or the user interface 106. Optionally, the tool path generation control unit 102 may be remotely located away from one or both of the structure database 104 and / or the user interface 106.

[0035] The incremental sheet forming system 100 also includes a forming tool or machine 108 configured to operate to form a structure 110. In at least one embodiment, the forming tool 108 is a forming stylus having a rounded, blunted operating end 112 configured to apply force to the structure 110 to form various features (e.g., curves, bends, recesses, and / or similar) in and / or on the structure 110. The forming tool 108 operates on the structure 110 according to a tool path 114 (e.g., via a predetermined tool path having a start and an end point) to form the desired shape of the structure 110.

[0036] In at least one embodiment, structure 110 is an initial structure, such as a metal (e.g., aluminum, titanium, copper, or similar alloy) blank. For example, the initial structure may be a flat, planar metal piece supported on a mold.

[0037] In at least one embodiment, the tool path generation control unit 102 communicates with the forming tool 108, such as via one or more wired or wireless connections. The tool path generation control unit 102 is configured to operate the forming tool 108 to form a desired shape of a target structure, which is formed, for example, from an initial structure such as sheet metal.

[0038] Structure database 104 stores various types of data. For example, structure database 104 stores target data 116. Target data 116 includes information related to the target or desired structure to be formed. For example, target data 116 may include discrete geometric definitions of the target structure to be formed, such as tessellation, which may include one or more inward features. For example, this may be in the form of an STL, PLY, or VRML file. Optionally, target data 116 may include a set of trimmed parametric surfaces, curves, and points. For example, this may be in the format of a STEP, SAT, Parasolids, or IGES file.

[0039] User interface 106 includes a display 118 and one or more interface devices, such as a monitor, television, touchscreen, keyboard, mouse, and / or the like. For example, user interface 106 and tool path generation control unit 102 may be part of a computer workstation. In at least another embodiment, tool path generation control unit 102 and user interface 106 may be part of a handheld device such as a smart tablet, smartphone, laptop, or the like.

[0040] In operation, the toolpath generation control unit 102 determines the size and shape of the target structure using target data 116. For example, target data 116 may include information related to the size, shape, and features of the target structure, as described above. In at least one embodiment, target data 116 may include target structure geometry data, convex hull geometry data, manufacturing process data, and toolpath data.

[0041] The tool path generation control unit 102 analyzes target data 116 relating to a target structure (such as the geometric definition of the target structure) and determines a convex hull for such a target structure. For example, in at least one embodiment, the tool path generation control unit 102 includes a convex hull determination module 120 that analyzes target data (e.g., subdivisions of the target structure) relating to the target structure and determines a convex hull for the target structure.

[0042] The convex hull of a point set S is a minimal convex set containing points S. For a target structure, the convex hull is a minimal convex set containing all points of the target structure. In the example, the tool path generation control unit 102 is configured to determine the convex hull of the target structure based on the minimal convex set containing all points of the target structure. The convex hull (C) of a point set is a set of every possible convex combination of the point set, as described by the following equation:

[0043]

[0044] Where p i It is the i-th cooperation point p

[0045] After the tool path generation control unit 102 determines the convex hull for the target structure, it operates the forming tool 108 relative to the structure 110 (such as a metal blank) according to a first tool path to form an intermediate structure based on the convex hull of the target structure. In the example, the shape of the intermediate structure to be formed may be selected based on the convex hull of the target structure. In at least one embodiment, the intermediate structure has a shape based on the convex hull of the target structure. For example, in at least one embodiment, the tool path generation control unit 102 includes a convex hull tool path generation module 122 (which may also be referred to as a first tool path generation module) that determines a first tool path based on the determined convex hull (and may then save the tool path, such as an ASCII text file in a format such as G-Code or APT source), and operates the forming tool 108 to form an intermediate structure with convex hull shaping based on the target structure (e.g., having a shape based on the convex hull of the target structure). In at least one embodiment, the first tool path is a Z-layer tool path for the forming tool 108.

[0046] In at least one embodiment, the shape of the intermediate structure is configured to resemble the convex hull of the target structure. For example, the intermediate structure formed by the convex hull of the target structure may include one or more inward features, or partially form inward features, while the convex hull does not include these inward features.

[0047] After the tool path generation control unit 102 operates or provides instructions for operating the forming tool 108 to form an intermediate structure, the forming tool is operated relative to the intermediate structure according to the instructions to traverse a second tool path to form various features of the target structure relative to the intermediate structure, thereby forming the target structure from the intermediate structure. The second tool path differs from the first tool path. For example, in at least one embodiment, the tool path generation control unit 102 includes or otherwise communicates with a target structure tool path generation module 124 (which may also be referred to as a second tool path generation module), which determines the second tool path based on a subdivision of the target structure, which may include inward features to be formed. A control unit (such as the tool path generation control unit 102 or a separate and distinct forming control unit 103 operatively coupled to the forming tool 108) operates the forming tool 108 to form the target structure from the intermediate structure. In at least one embodiment, the second tool path is a lace tool path for the forming tool 108.

[0048] As described herein, and as an example, forming control unit 103 receives instructions from toolpath generation control unit 102 to operate forming tool 108. As another alternative example, toolpath generation control unit 102 may directly operate forming tool 108. In at least one embodiment, toolpath generation control unit 102 and forming control unit 103 may be independent and distinct control units. As another example, toolpath generation control unit 102 and forming control unit 103 may be part of a common processing or control system or unit. For example, toolpath generation control unit 102 and forming control unit 103 may be part of an integrated chip, processing device, and / or the like.

[0049] In the example, as the tool path generation control unit 102 operates the forming tool 108 to form the target structure from the intermediate structure, the forming tool 108 forms one or more inward features into the intermediate structure having a shape with a convex hull based on the target structure. Thus, in the example, the inward features are formed after the convex hull is formed. Instead of forming the target structure in a single stage, where the forming tool 108 operates on the structure according to a single tool path to form the target structure, the forming tool 108 first operates relative to an initial structure (such as a metal blank) according to a first tool path (e.g., operating tool path 108 via a predetermined tool path having a start and an end point) to first form an intermediate structure having a shape with a convex hull based on the target structure. After forming the intermediate structure, the forming tool 108 then operates relative to the intermediate structure according to a second tool path to form one or more inward features relative to (e.g., on top of and / or within) the intermediate structure to form the target structure. By first forming a convex hull and then forming an inward feature into the convex hull, even if some parts of the structure are at steep angles (which risk damaging the steep walls when forming the inward feature compared to a single-pass incremental sheet forming process), embodiments of this disclosure result in less thinning and present a reduced risk of material damage.

[0050] Inward features are features formed into the outer wall of a structure. For example, inward features include recesses, cavities, notches, channels, depressions, grooves, dents, pits, indentations, holes, or similar features.

[0051] As described herein, a multi-stage incremental sheet forming system 100 includes a forming tool 108 and a tool path generation control unit 102, which communicates directly and / or via a forming control unit 103 with the forming tool 108. The tool path generation control unit 102 is configured to determine the convex hull (such as the convex hull of a geometric representation of a target structure) of a target path formed by the forming tool. The tool path generation control unit 102 is configured to operate the forming tool 108 according to a first tool path relative to an initial structure (e.g., a sheet metal blank, such as structure 110) to form an intermediate structure (e.g., a convex hull shaped to the target structure) based on the convex hull of the target structure. The tool path generation control unit 102 is further configured to operate the forming tool 108 according to a second tool path relative to the intermediate structure to form one or more inward features into the intermediate structure to form the target structure.

[0052] Figure 2 A flowchart of a multi-stage incremental sheet forming method according to embodiments of the present disclosure is shown. In at least one embodiment, one or more control units (such as tool path generation control unit 102 and forming control unit 103) operate according to the illustrated flowchart and regarding... Figure 2 The described operation.

[0053] refer to Figure 1 and Figure 2 At point 200, the tool path generation control unit determines the convex hull of the target structure. For example, the tool path generation control unit 102 (such as the convex hull determination module 122) analyzes the target data 116, which includes a geometric representation of the target structure, and determines the convex hull for the target structure (that is, determines the convex hull for the geometric representation of the target structure).

[0054] At point 202, an intermediate structure with a convex hull shape based on the target structure is formed. For example, a tool path generation control unit 102 (such as a convex hull tool path generation module 122) outputs instructions for operating a forming tool on an initial structure (such as a metal blank) according to (e.g., along its traverse) a first tool path to form an intermediate structure with a convex hull shape based on the target structure.

[0055] If an intermediate structure has been successfully formed (e.g., if the convex hull of the target structure has been fully formed), the method proceeds to 206, where one or more inward features are formed relative to the intermediate structure. For example, the tool path generation control unit 102 (such as the target structure path generation module 124) outputs instructions for manipulating the forming tool 108 on the intermediate structure according to a second tool path to form the inward features. If all inward features of the target structure are formed relative to the intermediate structure, the method proceeds to 210, where the target structure is formed.

[0056] As used herein, the terms “control unit,” “central processing unit,” “unit,” “CPU,” “computer,” or similar terms can include any processor-based or microprocessor-based system that utilizes a microcontroller, a reduced instruction set computer (RISC), an application-specific integrated circuit (ASIC), logic circuitry, and any other hardware, software, or combination thereof capable of executing the instructions described herein. This is merely illustrative and is therefore not intended to limit the definition and / or meaning of such terms in any way. For example, toolpath generation control unit 102 and shaping control unit 103 may be or include one or more processors configured to operate as described herein.

[0057] A module is one or more parts of a control unit. For example, a module may be part of a chip, circuit, processor, or the like. As another example, a module may be a chip, circuit, processor, or the like. Typically, a module may be a sub-control unit. For example, convex hull determination module 120, convex hull tool path generation module 122, and target structure tool path generation module 124 are components of tool path generation control unit 102.

[0058] The tool path generation module 124 and the forming control unit 103 are configured to execute a set of instructions stored in one or more data storage units or elements (such as one or more memories) to process data. For example, the tool path generation control unit, tool path generation control unit 102, and forming control unit 103 may include or be coupled to one or more memories. The data storage units may also store data or other information as desired or required. The data storage units may be in the form of physical memory elements in an information source or processing machine. One or more data storage units or elements may comprise volatile memory or non-volatile memory, or may comprise both volatile memory and non-volatile memory. As an example, non-volatile memory may comprise read-only memory (ROM), programmable ROM (PROM), electrically programmable ROM (EPROM), electrically erasable PROM (EEPROM), and / or flash memory, and volatile memory may include random access memory (RAM) that can be used as external cache memory. The data storage of the disclosed systems and methods is intended to include, but is not limited to, these and any other suitable types of memory.

[0059] The instruction set may include various commands instructing the tool path generation control unit 102 and the shaping control unit 103 as processing machines to perform specific operations of methods and processes according to various embodiments of the subject matter described herein. The instruction set may be in the form of a software program. This software may be in any form, such as system software or application software. Furthermore, the software may be a separate set of programs, a subset of programs within a larger program, or a part of a program. The software may also include modular programming in the form of object-oriented programming. Processing of the output data of the processing machine may be in response to user commands, the results of previous processing, or a request made by another processing machine.

[0060] The diagrams in the embodiments herein illustrate one or more control or processing units, such as tool path generation control unit 102 and shaping control unit 103. It should be understood that a processing or control unit may represent a circuit, circuit system, or portion thereof that can be implemented as hardware with associated instructions (e.g., software stored on a tangible and non-transient computer-readable storage medium, such as a computer hard disk, ROM, RAM, or the like) to perform the operations described herein. The hardware may include a hard-wired state machine circuit system to perform the functions described herein. Optionally, the hardware may include electronic circuitry comprising and / or connected to one or more logic-based devices, such as microprocessors, processors, controllers, or the like. Optionally, tool path generation control unit 102 and shaping control unit 103 may represent processing circuitry such as field-programmable gate arrays (FPGAs), application-specific integrated circuits (ASICs), microprocessors, and / or the like. The circuitry in the various embodiments may be configured to execute one or more algorithms to perform the functions described herein. One or more algorithms may include aspects of the embodiments disclosed herein, whether or not explicitly indicated in the flowcharts or methods.

[0061] As used herein, the terms “software” and “firmware” are interchangeable and include any computer program for computer execution stored in a data storage unit (e.g., one or more memories), including RAM memory, ROM memory, EPROM memory, EEPROM memory, and non-volatile RAM (NVRAM) memory. The above data storage unit types are merely exemplary and are therefore not limited to the types of memory that can be used to store computer programs.

[0062] Figure 3 A perspective view of a target structure 300 according to an embodiment of the present disclosure is shown. The target structure 300 is the structure to be formed. In at least one embodiment, the target structure 300 has one or more walls 302. In at least one embodiment, the target structure 300 has one or more walls 302 that collectively form at least one inwardly curved arched feature 306. As an example, the walls 302 are disposed at an angle of 40 degrees or more (e.g., 60 degrees or more) relative to a reference plane 304 relative to the target structure 300. For example, the reference plane 304 is a reference plane (such as the XY plane) orthogonal to the Z-axis in a Cartesian coordinate system. In the example, a portion of at least one wall 302 corresponding to the inwardly curved feature 306 includes one or more portions disposed at an angle of 60 degrees or more relative to the reference plane 304.

[0063] The target structure 300 includes at least one inward feature 306 embedded in at least one wall 302. For example, the inward feature 306 may be or include a recess 307, such as an inwardly pointing feature. As shown, the inward feature includes a cavity 309 extending inward from the outer envelope 308 of the wall 302. The outer envelope 308 is the outermost surface of the wall 302.

[0064] refer to Figure 1 and Figure 3 The target data 116 includes information relating to the target structure 300. For example, the target data 116 includes information relating to the size, shape, and inward features 306 of the target structure 300. In at least one embodiment, the target database 104 also stores manufacturing data (which may be included in the target data 116 or stored separately), the manufacturing data including information about tool type, tool shape, tool size, and tool feed rate.

[0065] Figure 4 The target structure 300 according to an embodiment of the present disclosure is shown (in) Figure 3 A perspective view of the intermediate structure 400 of the convex hull (shown in the figure). As shown, the intermediate structure 400 is the convex hull of the target structure 300.

[0066] refer to Figure 1 , Figure 3 and Figure 4 The tool path generation control unit 102 determines the convex hull of the target structure 300. Then, the tool path generation control unit 102 determines a first tool path based on the convex hull of the target structure 300. Then, the forming control unit 103, according to the first tool path, shapes the initial structure (such as in...) Figure 1 The structure 110 shown is operated on to form the intermediate structure 400.

[0067] The intermediate structure 400 of the convex hull of the target structure 300 has no inward feature 306. For example, the wall 402 of the intermediate structure 400 is smooth without an inward feature.

[0068] Figure 5 This illustrates the operation of the forming tool 108 according to the first tool path 500 to form Figure 4 A perspective view of the intermediate structure 400. (Reference) Figure 1 and Figure 5 The first toolpath 500 can be a Z-layer toolpath, in which the forming tool 108 engages (e.g., is driven into) the initial structure 110 at the horizontal plane or Z-layer 502 to form a convex hull that is the target structure 300. Figure 3 The intermediate structure 400 (as shown in the diagram). Adjacent Z layers 502 are separated by a predetermined space 504.

[0069] Figure 6 This illustrates the operation of the forming tool 108 according to the second tool path 600 to form Figure 3 A three-dimensional view of the target structure. (Reference) Figure 1 and Figure 6 The second tool path 600 can be a decorative tool path that alternates between backward and forward along the direction of arrow A (e.g., along an X or Y direction orthogonal to the Z direction) in the middle structure to form an inward feature 306. The first tool path (in Figure 5 The Z-layer path (as shown) moves along the contour in the XY plane while advancing along the Z direction, while the lace path of the second tool path 600 moves backward and forward while advancing along the X direction, such as alternating from side to side (or end to end). This forms the intermediate structure 400 (as shown). Figure 4 (As shown) After that, the forming tool 108 operates according to the second tool path 600, thereby forming the inward feature 306 into the intermediate structure 400 to form the target structure 300.

[0070] Figure 7 A perspective view of a target structure 700 according to an embodiment of the present invention is shown. The target structure 700 is the structure to be formed. In at least one embodiment, the target structure 700 has one or more walls 702 that collectively form at least one inward feature 706, which is shown as an arcuate cavity. As an example, the wall 702 has a maximum wall angle of 60 degrees or more relative to a reference plane 704.

[0071] The target structure 700 includes at least one inward feature 706 formed in at least one wall 702. As shown, the inward feature 706 includes a recess 707 having a notch 709 and / or one or more notches 711 extending inward from the outer envelope 708 of the wall 702.

[0072] Figure 8 The target structure 700 according to an embodiment of the present disclosure is shown (in Figure 7 A perspective view of the intermediate structure 800 of the convex hull (shown in the figure). As shown, the intermediate structure 800 is the convex hull of the target structure 700.

[0073] The intermediate structure 800 of the convex hull of the target structure 700 has no inward feature 706. For example, the wall 802 of the intermediate feature 800 is smooth and has no inward forming portion corresponding to the inward feature 706 of the target structure 700.

[0074] Figure 9 This illustrates the operation of a forming tool according to a first tool path 900 to form... Figure 8 A perspective view of the intermediate structure 800. (Reference) Figure 1 and Figure 9 The first tool path can be a Z-layer tool path, in which the forming tool 108 engages (e.g., is driven into) the structure 110 at the vertical plane or Z layer to form the intermediate structure 800.

[0075] Figure 10 A perspective view is shown of the forming tool 108 operating according to the second tool path 1000 to form the target structure. (Reference) Figure 1 and Figure 10 The second tool path 1000 can be a decorative tool path that alternates between backward and forward along the direction of arrow A (e.g., along the X or Y direction orthogonal to the Z direction) in the middle structure to form an inward feature 706. The first tool path 900 (in Figure 9 The Z-layer path (shown) moves along the contour in the XY plane while advancing in the Z direction, while the lace path of the second tool path 1000 moves backward and forward while advancing in the X direction, such as alternating from side to side (or end to end). This is used to form the intermediate structure 800 (in... Figure 8 (As shown in the diagram) After that, the forming tool 108 operates according to the second tool path 1000, thereby forming the inward feature into the intermediate structure 800 to form the target structure 700.

[0076] Figure 11 A perspective view of a target structure 1100 according to an embodiment of the present disclosure is shown. The target structure 1100 includes a plurality of inward features 1102, such as grooves 1101, channels 1103, and recesses 1105 between peaks 1104.

[0077] Figure 12 The embodiment of the present disclosure is shown as follows: Figure 11 A perspective view of the intermediate structure 1200 of the convex hull of the target structure 1100. The intermediate structure 1200 is not in... Figure 11 The inward feature 1102 shown.

[0078] Figure 13 A perspective view of a target structure 1300 according to an embodiment of the present disclosure is shown. The target structure 1300 includes a plurality of inward features 1302, such as holes or central passages 1304 and outward recesses 1306.

[0079] Figure 14 The embodiment of the present disclosure is shown as follows: Figure 13 A perspective view of the intermediate structure 1400 of the convex hull of the target structure 1300. The intermediate structure 1400 is not in... Figure 13 The inward feature 1302 shown.

[0080] Figure 3 , Figure 7 , Figure 11 and Figure 13 An example of the target structure is shown, and Figure 4 , Figure 8 , Figure 12 and Figure 14 An example of an intermediate structure is shown, which correspondingly represents the convex hull of the target structure mentioned earlier. It should be understood that such target and intermediate structures are merely examples. The target structure can be sized and shaped differently and can have more or less inward features (as shown or shaped differently from what is shown). Therefore, the relevant intermediate shape selected based on the convex hull of the target structure can be sized and shaped differently from what is shown.

[0081] refer to Figure 1-14 Embodiments of this disclosure provide systems and methods that allow for the rapid and efficient analysis of large amounts of data using computing devices. For example, a target structure may comprise tens of millions, rather than millions, of points connected by polygons such as triangles. Furthermore, manually manipulating a forming tool to correctly form intermediate and target structures may not be efficient. Thus, large amounts of data are analyzed, and the operation of the forming tool 108 is performed automatically based on this analysis. As described above, a massive amount of data is efficiently organized and / or analyzed by a tool path generation control unit 102, which further operates and / or outputs instructions for manipulating the forming tool 108. The tool path generation control unit 102 analyzes the data in a relatively short time to quickly and efficiently determine the size and shape of intermediate structures, generate a first tool path, form the intermediate structure, generate a second tool path, and form the target structure. Humans will be able to efficiently analyze such massive amounts of data in such a short time. Thus, embodiments of this disclosure provide enhanced and efficient functionality and superior performance regarding human analysis of massive amounts of data.

[0082] In at least one embodiment, components of the multi-stage incremental sheet forming system 100, such as the tool path generation control unit 102, provide and / or enable the computer system as a dedicated computer system for operation of the incremental sheet forming process.

[0083] As described herein, embodiments of this disclosure provide systems and methods for forming structures with steep walls (e.g., walls at angles of 60 degrees or greater) through incremental sheet forming. Furthermore, embodiments of this disclosure provide incremental sheet forming systems and methods that are resistant to damage (e.g., tearing) of structural material at steep angles (e.g., 60 degrees or greater).

[0084] Although various spatial and directional terms, such as upper, bottom, lower, middle, side, horizontal, vertical, front, and similar, may be used to describe embodiments of this disclosure, it should be understood that such terms are used only relative to the orientation shown in the drawings. Orientation may be inverted, rotated, or otherwise altered such that an upper part is a lower part, or vice versa, horizontal becomes vertical, and so on.

[0085] As used herein, structures, definitions, or elements “configured to” perform a task or operation are specifically structurally formed, constructed, or adapted in a manner corresponding to the task or operation. For clarity and to avoid ambiguity, objects that are merely capable of being modified to perform a task or operation are not “configured to” perform the task or operation as used herein.

[0086] It should be understood that the above description is intended to be illustrative rather than restrictive. For example, the above embodiments (and / or aspects thereof) can be used in combination with each other. Furthermore, many modifications can be made to adapt particular situations or materials to the teachings of various embodiments of the invention without departing from its scope. Although the dimensions and types of materials described herein are intended to define parameters of various embodiments of the invention, these embodiments are by no means limiting and are exemplary embodiments. Many other embodiments will be apparent to those skilled in the art upon review of the above description. Therefore, the scope of the various embodiments of the invention should be determined by reference to the appended claims, together with the full scope of the equivalents granted by those claims. In the appended claims and the detailed description herein, the terms “comprising” and “therein” are used as plain English equivalents to the corresponding terms “including” and “wherein”. Furthermore, the terms “first,” “second,” and “third,” etc., are used merely as labels and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in the form of means plus function, nor are they intended to be interpreted based on 35 USC §112(f), unless and until such claims are limited by the explicit use of the phrase “means for,” followed by an invalid further structural functional statement.

[0087] Furthermore, this disclosure includes embodiments pursuant to the following provisions:

[0088] Clause 1. A multi-stage incremental sheet forming system (100), comprising:

[0089] Forming tool (108); and

[0090] At least one control unit (102) communicating with the forming tool (108),

[0091] The at least one control unit (102) is configured to determine the convex hull of the target structure (300, 700, 1100) to be formed by the forming tool (108).

[0092] The at least one control unit (102) is configured to operate a forming tool (108) relative to the initial structure (110) according to a first tool path (114) to form an intermediate structure (400, 800, 1400) having a shape of a convex hull based on the target structure (300, 700, 1100), and

[0093] The at least one control unit (102) is configured to operate a forming tool (108) relative to intermediate structures (400, 800, 1400) according to a second tool path (114) to form one or more inward features (306, 706, 1302) into the intermediate structures (400, 800, 1400) to form a target structure (300, 700, 1100), wherein the second tool path (114) is different from the first tool path.

[0094] Clause 2. The multi-stage incremental sheet forming system (100) according to Clause 1, wherein the at least one control unit (102) comprises:

[0095] A tool path generation control unit (102) is configured to determine at least one tool path (114) and the convex hull of the target structure (300, 700, 1100); and

[0096] A forming control unit (103) is configured to operate a forming tool (108).

[0097] Clause 3. The multi-stage incremental sheet forming system (100) according to Clause 1 or Clause 2, wherein the at least one control unit (102) comprises: the tool path generation control unit (102) configured to determine the convex hull of the target structure (300, 700, 1100) based on the minimum convex set containing all points of the target structure (300, 700, 1100).

[0098] Clause 4. The multi-stage incremental sheet forming system (100) according to any one of Clauses 1 to 3 further includes a structure database (104) in communication with the at least one control unit (102), wherein the structure database (104) stores target data (116) including information relating to the size of the target structure, the shape of the target structure, one or more inward features (306, 706, 1302) of the target structure (300, 700, 1100), and manufacturing data including tool shape, tool size, and tool feed rate.

[0099] Clause 5. The multi-stage incremental sheet forming system (100) according to any one of Clauses 1 to 4, wherein the at least one control unit (102) comprises: a tool path generation control unit (102) including a convex hull determination module (120) that analyzes target data (116) relating to target structures (300, 700, 1100) and determines the convex hull of the target structures (300, 700, 1100) based on the target data (116).

[0100] Clause 6. The multi-stage incremental sheet forming system (100) according to any one of Clauses 1 to 5, wherein the at least one control unit (102) includes a tool path generation control unit (102) comprising a convex hull tool path generation module (122) that determines a first tool path based on the determined convex hull, and wherein the forming control unit (103) operates a forming tool (108) relative to an initial structure (110) according to the first tool path (114) to form an intermediate structure (400, 800, 1400) having a shape of a convex hull based on a target structure (300, 700, 1100).

[0101] Clause 7. The multi-stage incremental sheet forming system (100) according to any one of Clauses 1 to 6, wherein the first tool path (114) is the Z-layer (502) tool path (114).

[0102] Clause 8. The multi-stage incremental sheet forming system (100) according to any one of Clauses 1 to 7, wherein the at least one control unit (102) comprises: a tool path generation control unit (102) including a target structure tool path generation module (124) configured to operate or output, or both operate and output, instructions for operating a forming tool (108) relative to the intermediate structures (400, 800, 1400) according to a second tool path (114) to form one or more inward features (306, 706, 1302) into the intermediate structures (400, 800, 1400) to form the target structure (300, 700, 1100).

[0103] Clause 9. A multi-stage incremental sheet forming system (100) according to any one of Clauses 1 to 8, wherein the second tool path (114) is a lace tool path (114).

[0104] Clause 10. A multi-stage incremental sheet forming system (100) according to any one of Clauses 1 to 9, wherein one or more inward features (306, 706, 1302) comprise one or more of at least one recess (707), at least one cavity, at least one notch (711), at least one channel (1103), at least one recess (1105), at least one groove (1101), at least one indentation (709), at least one cavity (309), at least one recess (307), or at least one hole (1304).

[0105] Clause 11. A multi-stage incremental sheet forming system (100) according to any one of Clauses 1 to 10, wherein the target structure (300, 700, 1100) includes at least one wall disposed at an angle of at least 60 degrees relative to a horizontal plane.

[0106] Clause 12. A multi-stage incremental sheet forming system (100) according to any one of Clauses 1 to 11, wherein the intermediate structures (400, 800, 1400) do not have one or more inward features (306, 706).

[0107] Clause 13. A multi-stage incremental sheet forming method, comprising:

[0108] The convex hull of the target structure (300, 700, 1100) to be formed by the forming tool (108) is determined by at least one control unit (102);

[0109] The at least one control unit (102) operates the forming tool (108) relative to the initial structure (110) according to the first tool path (114) to form an intermediate structure (400, 800, 1400) having a convex hull shape based on the target structure (300, 700, 1100); and

[0110] The at least one control unit (102) operates the forming tool (108) relative to the intermediate structures (400, 800, 1400) according to the second tool trajectory (114) to form one or more inward features (306, 706, 1302) into the intermediate structures (400, 800, 1400) to form the target structure (300, 700, 1100), wherein the second tool trajectory (114) is different from the first tool trajectory (114).

[0111] Clause 14. The multi-stage incremental sheet forming method according to Clause 13 further includes storing target data (116) in a structure database (104), the target data (116) including information relating to the geometric representation of target structures (300, 700, 1100), the target structures (300, 700, 1100) including one or more inward features (306, 706, 1302) of the target structures (300, 700, 1100).

[0112] Clause 15. The multi-stage incremental sheet forming method according to Clause 13 or Clause 14, wherein the determination includes determining the convex hull of the target structure (300, 700, 1100) by means of the convex hull determination module (120).

[0113] Clause 16. The multi-stage incremental sheet forming method according to any one of Clauses 13 to 15, wherein the operation of the forming tool (108) by the at least one control unit (102) according to the first tool trajectory (114) comprises operating the forming tool (108) relative to the initial structure (110) by the convex hull tool trajectory generation module (122) according to the first tool trajectory (114) to form an intermediate structure (400, 800, 1400) having a convex hull shape based on the target structure (300, 700, 1100).

[0114] Clause 17. A multi-stage incremental sheet forming method according to any one of Clauses 13 to 16, wherein the first tool trajectory (114) is a Z-layer (502) tool trajectory (114), and wherein the second tool trajectory (114) is a lace tool trajectory (114).

[0115] Clause 18. A multi-stage incremental sheet forming method according to any one of Clauses 13 to 17, wherein the operation of the forming tool (108) by the at least one control unit (102) according to a second tool path (114) comprises operating the forming tool (108) relative to an intermediate structure (400, 800, 1400) by a target structure tool path generation module (124) according to the second tool path (114) to form one or more inward features (306, 706, 1302) into the intermediate structure (400, 800, 1400) to form a target structure (300, 700, 1100).

[0116] Clause 19. A multi-stage incremental sheet forming method according to any one of Clauses 13 to 18, wherein the one or more inward features (306, 706, 1302) comprises one or more of at least one recess, at least one cavity, at least one notch (711), at least one channel (1103), at least one recess (1105), at least one groove (1101), at least one indentation (709), at least one cavity (309), at least one recess (307), or at least one hole (1304).

[0117] Clause 20. A multi-stage incremental sheet forming method according to any one of Clauses 13 to 19, wherein the target structure (300, 700, 1100) includes at least one wall disposed at an angle of at least 60 degrees relative to a reference plane (304, 704).

[0118] Clause 21. A multi-stage incremental sheet forming method according to any one of Clauses 13 to 20, wherein the intermediate structures (400, 800, 1400) do not have one or more inward features (306, 706).

[0119] Clause 22. A multi-stage incremental sheet forming system (100), comprising:

[0120] Forming tool (108);

[0121] At least one control unit (102) communicating with the forming tool (108); and

[0122] A structural database (104) communicating with the at least one control unit (102), wherein the data structure (104) stores target data (116) including information relating to the geometric representation of the target structure (300, 700, 1100) and one or more internal features (306, 706, 1302) of the target structure (300, 700, 1100), wherein the one or more internal features (306, 706, 1302) include one or more of at least one recess, at least one cavity, at least one notch (711), at least one channel (1103), at least one recess (1105), at least one groove (1101), at least one indentation (709), at least one cavity (309), at least one indentation (307), or at least one hole (1304).

[0123] The at least one control unit (102) includes:

[0124] A convex hull determination module (120) is configured to determine the convex hull of the target structure (300, 700, 1100) to be formed by the forming tool (108);

[0125] A convex hull toolpath generation module (122) is configured to operate or output, or both operate and output, instructions for operating a forming tool (108) relative to an initial structure (110) based on a Z-layer (502) toolpath (114) to form intermediate structures (110, 400) having a shape based on the convex hull of the target structures (300, 700, 1100), wherein the intermediate structures (400, 800, 1400) do not have one or more inward features (306, 706); and

[0126] The target structure tool path generation module (124) is configured to operate or output, or both operate and output, instructions for operating the forming tool (108) relative to the intermediate structure (400, 800, 1400) according to the lace tool path (114) to form one or more inward features (306, 706, 1302) into the intermediate structure (400, 800, 1400) to form the target structure (300, 700, 1100).

[0127] This written description uses examples to disclose various embodiments of this disclosure, including the best mode, and also enables any person skilled in the art to practice various embodiments of this disclosure, including making and using any device or system and methods for performing any combination. The patentable scope of the various embodiments of this disclosure is defined by the claims, and may include other examples generated by those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that differ from the wording of the claims, or if they include equivalent structural elements that are not substantially different from the wording of the claims.

Claims

1. A multi-stage incremental sheet forming system (100), comprising: Forming tool (108); and At least one control unit (102) communicating with the forming tool (108), The at least one control unit (102) is configured to determine the convex hull of the target structure (300, 700, 1100) to be formed by the forming tool (108). The at least one control unit (102) is configured to operate the forming tool (108) relative to the initial structure (110) according to a first tool path (114) to form an intermediate structure (400, 800, 1400) having a shape of the convex hull based on the target structure (300, 700, 1100), and The at least one control unit (102) is configured to operate the forming tool (108) relative to the intermediate structure (400, 800, 1400) according to a second tool path (114) to form one or more inward features (306, 706, 1302) into the intermediate structure (400, 800, 1400) to form the target structure (300, 700, 1100), wherein the second tool path (114) is different from the first tool path (114).

2. The multi-stage incremental sheet forming system (100) according to claim 1, wherein the at least one control unit (102) comprises: A tool path generation control unit (102) is configured to determine at least one tool path (114) and the convex hull of the target structures (300, 700, 1100); and A forming control unit (103) is configured to operate the forming tool (108).

3. The multi-stage incremental sheet forming system (100) according to claim 1, wherein the at least one control unit (102) comprises: a tool path generation control unit (102) configured to determine the convex hull of the target structure (300, 700, 1100) based on a minimum convex set containing all points of the target structure (300, 700, 1100).

4. The multi-stage incremental sheet forming system (100) according to claim 1, further comprising a structure database (104) in communication with the at least one control unit (102), wherein the structure database (104) stores target data (116), the target data (116) including information relating to the size of the target structure, the shape of the target structure, one or more inward features (306, 706, 1302) of the target structure (300, 700, 1100), and manufacturing data including tool shape, tool size, and tool feed rate.

5. The multi-stage incremental sheet forming system (100) according to claim 1, wherein the at least one control unit (102) comprises: a tool path generation control unit (102) including a convex hull determination module (120) that analyzes target data (116) related to the target structure (300, 700, 1100) and determines the convex hull of the target structure (300, 700, 1100) based on the target data (116).

6. The multi-stage incremental sheet forming system (100) according to any one of claims 1 to 5, wherein the at least one control unit (102) comprises a tool path generation control unit (102), the tool path generation control unit (102) comprising a convex hull tool path generation module (122), the convex hull tool path generation module (122) determining a first tool path (114) based on a determined convex hull, and wherein the forming control unit (103) operates the forming tool (108) relative to the initial structure (110) according to the first tool path (114) to form the intermediate structure (400, 800, 1400) having the shape of the convex hull based on the target structure (300, 700, 1100).

7. The multi-stage incremental sheet forming system (100) according to any one of claims 1 to 5, wherein the at least one control unit (102) comprises: a tool path generation control unit (102) including a target structure tool path generation module (124), the target structure tool path generation module (124) being configured to operate or output, or both operate and output, instructions for operating the forming tool (108) relative to the intermediate structure (400, 800, 1400) according to the second tool path (114) to form the one or more inward features (306, 706, 1302) into the intermediate structure (400, 800, 1400) to form the target structure (300, 700, 1100).

8. The multi-stage incremental sheet forming system (100) according to any one of claims 1 to 5, wherein the one or more inward features (306, 706, 1302) comprises one or more of at least one recess (707), at least one cavity, at least one notch (711), at least one channel (1103), at least one recess (1105), at least one groove (1101), at least one indentation (709), at least one cavity (309), at least one recess (307), or at least one hole (1304).

9. The multi-stage incremental sheet forming system (100) according to any one of claims 1 to 5, wherein the target structure (300, 700, 1100) comprises at least one wall disposed at an angle of at least 60 degrees relative to a horizontal plane.

10. A multi-stage incremental sheet forming method, comprising: The convex hull of the target structure (300, 700, 1100) to be formed by the forming tool (108) is determined by at least one control unit (102); The forming tool (108) is operated by the at least one control unit (102) relative to the initial structure (110) according to the first tool path (114) to form an intermediate structure (400, 800, 1400) having the shape of the convex hull based on the target structure (300, 700, 1100); and The forming tool (108) is operated by the at least one control unit (102) relative to the intermediate structure (400, 800, 1400) according to the second tool path (114) to form one or more inward features (306, 706, 1302) into the intermediate structure (400, 800, 1400) to form the target structure (300, 700, 1100), wherein the second tool path (114) is different from the first tool path (114).

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