Incremental Forming Tool Path for Spring Back Compensation
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Solution Overview
Problem
Incremental forming technologies face challenges with dimensional inaccuracies due to spring back and residual stresses in workpieces, which affect the accuracy of forming new features and lead to unwanted plastic deformation.
Innovation Solution
A method is developed that involves determining a tool squeeze factor, generating a tool path based on normal vectors and the squeeze factor, and incrementally forming the workpiece from a point at maximum distance from a reference position, using tools that move along a spiral path to achieve the desired geometry while minimizing inaccuracies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If incremental forming is performed on workpieces with spring back and residual stresses, then the forming process can be completed, but dimensional inaccuracies and unwanted plastic deformation occur
Solution Approach 1:
The method performs preliminary classification of workpiece features and pre-calculation of normal vectors before the actual incremental forming process. By analyzing the workpiece geometry and determining forming strategies in advance, the system prepares optimal tool paths and forming parameters that account for spring back and residual stresses, thereby preventing dimensional inaccuracies before they occur during forming
Solution Approach 2:
The invention dynamically adjusts forming parameters including tool path generation based on classified features, normal vector orientations, and squeeze factor modifications. By changing these parameters adaptively according to the specific geometric features being formed, the system compensates for spring back effects and residual stress variations, maintaining dimensional accuracy throughout the forming process
2Ease of operation
If tools follow a simple path for incremental forming, then the process is easier to control, but dimensional inaccuracies increase due to spring back and residual stresses
Solution Approach 1:
The method segments the workpiece into distinct geometric features and classifies them according to their forming characteristics. By dividing the workpiece geometry into manageable feature categories, the system can generate specific tool paths for each feature type while maintaining overall process simplicity and controllability
Solution Approach 2:
The invention introduces normal vector calculations and feature classification as additional dimensions to the traditional incremental forming approach. By considering the orientation and geometric properties of surface normals alongside tool path planning, the system achieves more precise dimensional control without significantly complicating the overall process
Data Source
AI summary
A method of incrementally forming a workpiece. The method includes determining a desired workpiece geometry, generating a tool path in which a feature is formed outwardly from a point that is disposed a maximum distance from a reference position, and incrementally forming the workpiece.