Double-Sided Incremental Forming Toolpath Control
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Solution Overview
Problem
Existing incremental forming techniques face challenges in achieving accurate geometric shapes due to non-local deformation and springback, particularly in single point incremental forming, and require complex process planning and equipment for die-based and double-sided incremental forming, which can be time-consuming and costly.
Innovation Solution
A system and method utilizing two tools on opposite sides of a deformable sheet, with a control unit to move the tools in deformation directions and laterally, allowing for the creation of three-dimensional components without removing the sheet, using a control unit with input, equalization, sorting, point generation, and path writing modules to determine optimal toolpaths and maintain contact with the sheet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If single point incremental forming is used, then process flexibility is maintained, but geometric accuracy deteriorates due to non-local deformation and springback
Solution Approach 1:
The forming process is segmented into multiple incremental passes, with the toolpath divided into numerous small steps that progressively deform the sheet. This segmentation allows control of deformation at each stage, reducing non-local deformation effects and improving geometric accuracy while maintaining the flexibility of incremental forming.
Solution Approach 2:
Instead of using a single point tool as in traditional SPIF, the invention inverts the approach by using a distributed array of forming points that move in a coordinated manner. This inversion of the forming mechanism allows simultaneous control of multiple deformation zones, reducing springback and improving geometric accuracy.
2Manufacturing precision
If die-based incremental forming is used, then geometric accuracy is improved, but device complexity and cost increase due to requiring pre-formed dies
Solution Approach 1:
The invention extracts the forming function from a fixed die and relocates it to a programmable tool that can be positioned and oriented dynamically. This removes the need for pre-formed dies while maintaining geometric accuracy, reducing device complexity and enabling flexible production of different geometries.
Solution Approach 2:
The forming tool is made dynamic and programmable rather than static like a traditional die. The tool can be repositioned, reoriented, and reconfigured through software control, allowing the same equipment to produce various geometries without physical retooling, thus reducing complexity while maintaining precision.
3Manufacturing precision
If double-sided incremental forming is used, then geometric accuracy is improved, but time consumption increases due to requiring accurate thickness prediction and repetitive trials
Solution Approach 1:
The system incorporates feedback mechanisms that use actual sheet thickness measurements and deformation data from previous passes to adjust forming parameters in subsequent passes. This feedback loop eliminates the need for repetitive trials and accurate a-priori thickness prediction, reducing process time while maintaining geometric accuracy.
Solution Approach 2:
The invention performs preliminary characterization of the sheet material properties and conducts initial forming passes to establish baseline data before final precision forming. This preliminary action provides the information needed to optimize subsequent passes, reducing the need for time-consuming trials and improving overall process efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the formation of accurate three-dimensional components with improved geometric precision and flexibility, reducing the need for complex process planning and equipment, while maintaining contact between tools and the sheet throughout the forming process.
Implementation Method 1
a first tool on a first side of the sheet and a second tool on an opposite, second side of the sheet... to deform the sheet... in order to create a three-dimensional component from the sheet
Data Source
AI summary
A forming system includes first and second tools, moving assemblies, and a control unit. The moving assemblies move the first tool and the second tool relative to the sheet. The control unit is configured to control movement of the first tool and the second tool by the one or more moving assemblies by moving at least one of the first tool or the second tool in a first deformation direction to deform the sheet, then moving the first and second tools laterally relative to the sheet to a subsequent location while engaging the sheet, then moving at least one of the first tool or the second tool in the first deformation direction or an opposite second deformation direction to deform the sheet, and then continue moving the first and second tools to deform the sheet in order to create a three-dimensional component from the sheet.