Incremental Sheet Forming of Tailored Blanks for Shape and Thickness Control
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Solution Overview
Problem
Incremental sheet forming of sheet metal components often results in uneven thinning, residual stresses, and undesirable stiffness characteristics, which can lead to 'springback' tendencies and economic inefficiencies due to slow processing speeds.
Innovation Solution
A method of forming tailored blanks by altering the initial sheet metal blank through material addition or removal before and during the incremental sheet forming process, using systems like single-point or double-sided incremental sheet forming systems, to achieve specified thickness and stiffness variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If incremental sheet forming is used to form sheet metal components, then complex three-dimensional shapes can be achieved, but uneven localized thinning occurs making it difficult to manage thickness requirements
Solution Approach 1:
The patent applies preliminary action by modifying the blank before forming to pre-compensate for expected thinning. Different thickness regions are created in the blank prior to incremental sheet forming, allowing the final component to achieve uniform thickness despite the deformation process. This is accomplished through selective material addition or removal in specific zones before forming begins.
Solution Approach 2:
The patent implements local quality by creating spatially varying material properties in the blank. Different regions of the blank are tailored with different thicknesses or material characteristics to compensate for localized thinning during forming. This allows each region to be optimized for its specific deformation behavior, maintaining overall thickness control while achieving complex shapes.
2Adaptability or versatility
If incremental sheet forming is used, then customized sheet metal components can be produced, but residual stresses cause springback tendencies
Solution Approach 1:
The patent applies parameter changes by modifying material properties in different regions of the blank to control stress distribution. By varying thickness, material composition, or mechanical properties locally, the forming process generates more uniform stress distribution, reducing residual stresses and springback while maintaining customization capabilities.
3Productivity
If incremental sheet forming speed is increased to improve productivity, then processing time is reduced, but unplanned stress distribution and microstructure changes occur
Solution Approach 1:
The patent uses preliminary action by pre-configuring the blank with tailored thickness distributions that anticipate high-speed forming effects. This allows the material to better withstand rapid deformation without developing unplanned stress patterns or microstructure changes, enabling increased productivity while maintaining quality control.
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 improved compliance with specified geometries and reduced weight, while increasing forming speed and reducing energy requirements, allowing for more efficient and cost-effective production of sheet metal components with tailored properties.
Implementation Method 1
a flat, unitary blank of sheet metal is held in a fixture while at least one stylus is used to deform the blank into a desired three-dimensional shape
Data Source
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AI summary
A method of making a sheet metal component from a tailored blank includes altering an initial blank formed from a first material to form the tailored blank by at least one of (i) coupling additional material to a portion of the first material, and (ii) removing the first material from a portion of the initial blank. The method also includes forming the sheet metal component from the tailored blank by an incremental sheet forming process.