Double-Sided Incremental Forming for Sheet Bending Control
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Solution Overview
Problem
Current low volume production of sheet metal components is costly and inflexible due to the need for expensive, mass-produced dies, and existing incremental forming methods face challenges with unwanted sheet bending and deformation.
Innovation Solution
The implementation of a double-sided incremental forming system using two opposing tools with a current source to reduce forming forces and allow for precise control and flexibility in shaping sheet metal without the need for specific dies, utilizing a gantry-style axis assembly for accurate positioning and a thermal imaging camera for temperature monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If single point incremental forming is used, then the need for expensive dies is eliminated, but unwanted sheet bending and deformation occur
Solution Approach 1:
The patent transitions from single-sided incremental forming to double-sided incremental forming, adding a second tool acting on the opposite side of the sheet metal. This dimensional change allows simultaneous support and forming actions, preventing unwanted bending and deformation while maintaining the elimination of expensive dies.
Solution Approach 2:
The second tool acts as a counterbalancing force to the first tool, providing support that counteracts unwanted sheet bending and deformation. This counteracting action enables precise control of sheet metal during forming without requiring expensive restraining dies.
2Manufacturing precision
If partial or full dies are used to support the sheet, then sheet bending is reduced, but high costs and low flexibility are re-introduced
Solution Approach 1:
The patent employs dynamic, programmable tool paths for both tools rather than static dies. The tools can be repositioned and reprogrammed to accommodate different part geometries, providing both the sheet control needed to reduce bending and the flexibility to adapt to various designs without costly die modifications.
Solution Approach 2:
The double-sided incremental forming system serves multiple functions: it provides sheet support, applies forming forces, and enables complex geometry creation all without requiring application-specific dies. This universal system replaces multiple specialized dies with a single flexible platform.
3Adaptability or versatility
If double-sided incremental forming is implemented, then flexibility and cost are improved, but forming forces remain high
Solution Approach 1:
The system introduces current to heat the sheet metal before and during the forming process, pre-softening the material to reduce the force required for deformation. This preliminary thermal action prepares the sheet to be more formable, allowing the incremental forming tools to shape the metal with reduced mechanical forces.
4Force
If high current is introduced through the sheet metal, then forming forces are reduced, but temperature control becomes critical
Solution Approach 1:
The system incorporates temperature monitoring and control mechanisms that provide feedback during the simultaneous heating and forming process. This feedback loop allows real-time adjustment of current and forming parameters to maintain optimal temperature ranges, ensuring material formability while preventing excessive heat that could damage the sheet metal.
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 reduces production costs, minimizes the reliance on application-specific tooling, enhances the mobility and user-friendliness of the equipment, and improves the control and accuracy of forming operations, enabling the production of a variety of shapes with reduced forming forces.
Implementation Method 1
a current source configured to deliver a current passing between the first tool positioning assembly and the second tool positioning assembly, wherein the current passes through the workpiece
Implementation Method 2
a thermal imaging camera configured to obtain thermal information of the workpiece and/or at least one of the first tool or the second tool
Data Source
AI summary
A system includes a frame configured to hold a workpiece and first and second tool positioning assemblies configured to be opposed to each other on opposite sides of the workpiece. The first and second tool positioning assemblies each include a toolholder configured to secure a tool to the tool positioning assembly, a first axis assembly, a second axis assembly, and a third axis assembly. The first, second, and third axis assemblies are each configured to articulate the toolholder along a respective axis. Each axis assembly includes first and second guides extending generally parallel to the corresponding axis and disposed on opposing sides of the toolholder with respect to the corresponding axis. Each axis assembly includes first and second carriages articulable along the first and second guides of the axis assembly, respectively, in the direction of the corresponding axis.