Curved Transition Tool Paths for Incremental Sheet Forming
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Solution Overview
Problem
Incremental sheet forming (ISF) using traditional tool path algorithms results in undesirable surface quality due to limitations in bi-directional toolpath capabilities and transition areas, particularly for concave or convex workpieces, as existing algorithms are suboptimal and do not account for continuous alternating curved transitions.
Innovation Solution
A method and system that divide the desired workpiece shape into layers, define circumferential paths for each layer, and calculate curved transitions to connect these paths, allowing the forming tool to move smoothly in alternating directions without lifting, thereby generating a tool path with planar parallel alternating paths connected by curved transitions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional tool path algorithms are used for incremental sheet forming, then the forming process can be completed, but undesirable surface quality results in transition areas
Solution Approach 1:
The tool path is segmented into distinct types: horizontal passes for general forming and curved transitions for connecting different levels. This segmentation allows each segment to be optimized for its specific function, with curved transitions specifically designed to eliminate surface defects in transition areas while horizontal passes maintain overall forming efficiency
Solution Approach 2:
Curved transitions are introduced instead of traditional linear or angular transitions between horizontal passes. The curved path allows the forming tool to smoothly change direction while maintaining continuous contact with the workpiece, eliminating the sharp transitions that cause surface defects while preserving forming precision
2Manufacturing precision
If traditional machining tool paths are used, then the forming operation can proceed, but distortion occurs in concave or convex workpieces
Solution Approach 1:
The tool path is pre-planned to include curved transitions that anticipate and prevent distortion before it occurs. By designing the transition paths in advance to follow the workpiece contour and alternating directions, the method prevents material stress concentration that would otherwise cause distortion in concave or convex areas, maintaining workpiece accuracy without requiring post-processing
Solution Approach 2:
The tool path alternates direction periodically between horizontal passes and curved transitions. This periodic alternating pattern distributes forming stress evenly across the workpiece, preventing cumulative distortion in specific areas while maintaining efficient forming progress through systematic coverage of the entire workpiece surface
3Ease of manufacture
If horizontal passes are used to intersect the design, then the forming process is simple, but transition areas create harmful surface defects
Solution Approach 1:
Curved transitions serve as intermediary elements between horizontal passes, mediating the change in tool direction while maintaining continuous forming contact. This intermediary curved path prevents the direct sharp transition between horizontal passes that would otherwise create surface defects, smoothly bridging the gap between different forming levels
Data Source
AI summary
A method is presented. A tool path having planar parallel alternating paths connected by a plurality of curved transitions is generated. A forming tool is driven along the planar parallel alternating paths and the plurality of curved transitions to shape a material into a workpiece.