Resilient Backing in Incremental Sheet Forming to Prevent Wrinkling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing sheet metal forming technologies face challenges in low-volume production and prototyping due to the high cost and long lead times associated with manufacturing and maintaining dies, and they often result in defects like wrinkling and tearing, especially in dual-sided incremental forming methods.
Innovation Solution
A dual-sided incremental sheet forming apparatus using a primary rigid tool and a secondary compressible tool with a resilient layer, allowing for localized force application and control, which reduces the need for purpose-built dies and minimizes defects by distributing forces accurately.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If dual-sided incremental forming methods are used, then forming capability is improved, but defects like wrinkling and tearing increase
Solution Approach 1:
The patent applies local quality by using a resilient backing material only at specific locations where support is needed during forming, rather than uniformly across the entire backing surface. This localized resilience provides targeted support to prevent wrinkling and tearing while maintaining forming capability in complex and asymmetric shapes.
Solution Approach 2:
The patent changes the physical parameter of the backing material from rigid to resilient, allowing it to deform and provide controlled support during the forming process. This parameter change enables the backing material to adapt to local stress conditions, preventing defects while maintaining forming capability.
2Manufacturing precision
If rigid dies are used for sheet metal forming, then manufacturing precision is improved, but production cost and lead time increase
Solution Approach 1:
The patent replaces expensive, permanently machined rigid dies with a simpler, reusable tooling system consisting of a forming tool and a resilient backing material. This approach eliminates the need for costly die manufacturing while maintaining sufficient forming precision for low-volume production and prototyping.
Solution Approach 2:
The patent creates a universal tooling system that can form various sheet metal parts without requiring dedicated dies for each part. The same forming tool and backing material setup can be used for different geometries, making the system adaptable for low-volume production of multiple part types.
3Device complexity
If single rigid die forming is used, then device complexity is reduced, but force distribution and defect control worsen
Solution Approach 1:
The patent applies local quality by providing resilient support at specific locations on the backing material where stress concentration occurs during forming. This localized resilience prevents wrinkling and tearing without requiring complex dual-sided tooling systems.
Solution Approach 2:
The patent introduces a resilient backing material as an intermediary between the rigid forming tool and the sheet metal workpiece. This intermediary absorbs and distributes forming forces, preventing defects while keeping the overall tooling system relatively simple.
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 the formation of complex and asymmetric shapes with reduced power consumption and increased precision, eliminating the need for expensive dies and reducing production time, while minimizing defects such as wrinkling and tearing.
Implementation Method 1
a secondary compressible tool with a resilient layer
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.