Dual-Sided Incremental Sheet Forming With Resilient Backing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing sheet metal forming technologies face challenges in efficiently forming complex shapes without the need for expensive and time-consuming die manufacturing, particularly in low-volume production and prototype development, as they often result in wrinkling and tearing due to inadequate force control.
Innovation Solution
A dual-sided incremental sheet forming method using a primary rigid tool and a secondary resilient tool, which applies localized forces to the sheet material, allowing for precise control and formation of complex shapes without the need for purpose-built dies, thereby reducing production costs and time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional stamping technology with rigid dies is used, then manufacturing precision and reliability are improved, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The invention extracts and removes the complex rigid die system from the forming process, retaining only a simple support structure while using a programmable forming tool to create the desired geometry directly on the sheet material, thereby simplifying the device while maintaining forming precision
Solution Approach 2:
Instead of using a physical rigid die that must be manufactured and maintained, the invention uses a digital model that guides the forming tool to copy the desired shape directly onto the sheet material, eliminating the need for complex physical tooling while preserving geometric accuracy
2Manufacturing precision
If rigid die stamping is used for low-volume production, then manufacturing precision is improved, but productivity and ease of manufacture worsen due to high die manufacturing costs and long lead times
Solution Approach 1:
The invention changes the fundamental parameter of tooling from fixed rigid dies to a programmable forming tool with variable forming paths, allowing the same tool to produce different geometries by changing control parameters rather than physical tooling, thereby enabling quick adaptation to different production requirements
Solution Approach 2:
The forming tool is designed to be universal and multi-functional, capable of forming various geometries and configurations on different sheet materials through programmable control, replacing the need for multiple specialized rigid dies and significantly improving productivity for low-volume and prototype production
3Device complexity
If single-sided incremental sheet forming is used to avoid die manufacturing, then device complexity is reduced, but manufacturing precision deteriorates due to wrinkling and tearing from inadequate force control
Solution Approach 1:
The invention introduces a resilient support tool as an intermediary element between the rigid support structure and the sheet material. This resilient layer acts as a mediator that provides controlled counter-pressure and support during forming, preventing wrinkling and tearing while maintaining the simplicity of the overall system
Solution Approach 2:
The invention changes the physical state and mechanical properties of the support interface by using a resilient material with specific elastic properties, allowing the support to adapt locally to the forming forces and maintain optimal contact pressure throughout the process, thereby improving forming quality without increasing device complexity
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 method enables the formation of complex and asymmetric shapes with improved precision and reduced power consumption, minimizing defects such as wrinkling and tearing, while eliminating the need for expensive die manufacturing.
Implementation Method 1
a secondary resilient tool, which applies localized forces to the sheet material, allowing for precise control and formation of complex shapes
Data Source
AI summary
The present invention is directed to a dual sided incremental sheet forming apparatus and method for incrementally forming sheet materials such as sheet metal by utilizing opposed primary and secondary forming tool assemblies and a sheet feeding assembly. The primary forming tool assembly includes a rigid tool and the secondary forming tool assembly includes a compressible and resilient backing layer having either a cylindrical or flat configuration. The sheet feeding assembly positions the sheet material between the two forming tools. The rigid tool applies force to one surface of the sheet material while the resilient backing tool applies counter force to the opposite surface of the work piece as it supports the work piece. This dual sided process localizes the forces on the sheet material so that stresses are advantageously controlled to produce accurately formed asymmetric shapes, without the need for expensive dies. The use of a rigid tool with an opposed resilient backing tool both having linear independent motion also avoids potential wrinkling and tearing of the resulting work piece and enables the formation of numerous, highly detained asymmetric products.