Automated Toolpath Generation for Double Sided Incremental Forming
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Solution Overview
Problem
Current CNC machining toolpaths are inadequate for double-sided incremental forming (DSIF) as they cannot generate synchronized paths for forming features on both sides of the sheet stock, leading to potential tool puncture and loss of contact between tools and the sheet, which affects geometric accuracy.
Innovation Solution
The method employs geometrically constructed maps to create a hierarchical rooted tree structure, allowing for automatic generation of synchronized toolpaths that can change forming order and direction, using maps to store feature relationships and tree traversal algorithms to ensure correct feature formation and tool movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If existing CNC machining toolpaths are used for double-sided incremental forming, then single direction machining is simple to generate, but the tools cannot form features on both sides of the sheet simultaneously and may puncture the workpiece
Solution Approach 1:
The toolpath generation process is segmented into multiple passes, with each pass forming a subset of features on one side of the sheet. The system divides the complete feature set into two groups (one for each tool side) and generates separate toolpaths for each pass, ensuring that features are formed in a controlled sequence that prevents tool puncture while maintaining manufacturing simplicity
Solution Approach 2:
The system dynamically adjusts the toolpath generation based on the current state of the workpiece. After each pass, the system updates the workpiece geometry and recalculates the remaining features to be formed, allowing the forming sequence and direction to change adaptively between passes while preventing tool puncture
2Adaptability or versatility
If manual toolpath sorting and stitching is performed for double-sided forming, then features can be formed on both sides, but the process requires multiple manual steps and reduces automation
Solution Approach 1:
The system performs self-service by automatically generating synchronized toolpaths for both tools without requiring manual intervention. The algorithm autonomously determines the forming sequence, divides features between the two tools, and generates the complete toolpath program, eliminating the need for manual contour separation, feature grouping, and toolpath stitching while maintaining full double-sided forming capability
3Ease of manufacture
If features are formed in fixed sequence from single direction, then toolpath generation is straightforward, but geometric accuracy is compromised when forming complex double-sided geometries
Solution Approach 1:
The system dynamically changes the forming direction and sequence between passes to optimize geometric accuracy. By updating the workpiece geometry after each pass and recalculating the remaining features, the system can adaptively select the most accurate forming approach for each subsequent pass, rather than being constrained to a fixed single-direction sequence
Solution Approach 2:
The system changes process parameters including forming direction, tool selection, and feature formation sequence between passes. By varying these parameters based on the current workpiece state and remaining features, the system achieves high geometric accuracy for complex double-sided geometries while maintaining straightforward automated toolpath generation
Data Source
AI summary
An automated method for generating toolpaths in double sided incremental forming (DSIF) operations is disclosed which uses a geometrically constructed map to build a structure of all the geometric features that is capable of tracking and forming the features in the correct order while simultaneously keeping track of the location of the virgin material. The aforementioned method allows toolpaths for complex geometries in the DSIF process to be generated automatically.