Incremental Sheet Forming With Resilient Tooling for Warp Control
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Solution Overview
Problem
Existing incremental sheet forming methods face challenges in achieving dimensional accuracy, tight tolerances, and reproducibility due to directional biases and localized stresses that can lead to warping and twisting of sheet materials.
Innovation Solution
The method involves alternating or reversing the direction of travel along adjacent paths or groups of paths during incremental forming, using a primary forming tool assembly and a compressible backing tool assembly to rebalance and diffuse localized stresses, thereby enhancing dimensional accuracy and reproducibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If incremental sheet forming is performed using conventional methods with unidirectional tool paths, then the forming process can be completed, but dimensional accuracy and reproducibility deteriorate due to directional biases and localized stresses causing warping and twisting
Solution Approach 1:
The patent applies inversion by reversing the direction of tool travel along adjacent paths. Instead of consistently moving in one direction (e.g., left-to-right for all paths), the tool alternates direction (left-to-right on one path, right-to-left on the next path). This reverses the directional bias of forming forces, causing stresses to diffuse and cancel out, thereby eliminating warping and twisting while improving dimensional accuracy and reproducibility
2Reliability
If incremental sheet forming is performed using conventional methods, then the forming process can be completed, but consistency and reproducibility of the final configuration deteriorate due to accumulated localized stresses
Solution Approach 1:
By inverting the tool travel direction on adjacent paths, the patent causes localized stresses to reverse direction and diffuse throughout the formed part. This stress diffusion prevents accumulation of localized stresses that would otherwise compromise consistency and reproducibility, leading to more reliable and repeatable forming results
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 the possibility of sheet metal warping and twisting, improving dimensional accuracy, tight tolerances, and consistency in the final configuration of sheet materials.
Implementation Method 1
the work piece compresses the resilient layer of the backing tool assembly to create localized forces on the work piece
Implementation Method 2
a compressible and resilient layer of material that is located adjacent to the work piece
Data Source
AI summary
A dual sided incremental sheet forming method for incrementally forming sheet materials such as sheet metal that provides opposed primary and secondary forming tool assemblies. The primary forming tool assembly provides a rigid tool and the secondary forming tool assembly provides a compressible and resilient backing layer. The rigid tool applies force to one surface of the 2024/054570 sheet material while the resilient backing tool applies counter force to the opposite surface of the work piece as it supports the work piece along predetermined, successive paths of formation created as the primary forming tool assembly moves relative to the sheet material. The direction of travel of the primary forming tool relative to the sheet material is alternated either as to each successive path of formation, or as to predetermined groupings of paths of formation.