Resilient Backing Tooling for Precise Incremental Sheet Forming

The patent uses a rigid master die to create a resilient backup die that copies the master die's shape and forming characteristics. This allows the system to achieve precision comparable to traditional rigid die stamping while avoiding the need to manufacture multiple expensive rigid dies for different parts. The resilient die acts as a reusable copy that can be rapidly produced through casting or molding processes.

The patent changes the physical state and properties of the backup die from rigid to resilient by using elastomeric or viscoelastic materials. This parameter change allows the backup die to deform elastically during forming operations, absorbing stress concentrations and preventing defects while maintaining forming precision. The resilient material properties can be tuned to match specific forming requirements.

The patent creates a master die with the precise forming geometry in advance, then uses it to produce resilient backup dies through rapid casting or molding processes. This preliminary action allows the system to achieve high forming precision while dramatically reducing the time required to produce tooling for low-volume production. The master die can be reused to create multiple backup dies as needed.

The resilient backup die is created as a copy of the master die through rapid prototyping, casting, or molding techniques. This copying process takes fractions of the time required to machine a traditional rigid die, enabling quick tooling production for prototypes and low-volume runs while maintaining the precision geometry of the original master die design.

The patent introduces a resilient backup die as an intermediary element between the rigid master die and the workpiece. This resilient intermediate layer mediates the force transmission during forming, distributing stresses evenly and preventing the wrinkling and tearing defects that occur in single-sided forming. The backup die acts as a cushion that maintains uniform contact pressure across the forming zone.

The patent employs a composite tooling system combining rigid master die material (for precision geometry) with resilient backup die material (for stress distribution). This composite approach leverages the advantages of both rigid and flexible materials, achieving defect-free forming while maintaining system simplicity and avoiding complex fluid pressure or backing material systems.

The patent employs an asymmetric dual-sided forming configuration where a rigid master die provides the primary forming action on one side, while a resilient backup die provides support on the opposite side. This asymmetric arrangement eliminates the need to coordinate the paths of two rigid tools, as the resilient backup die naturally conforms to the workpiece and master die interface, simplifying the control system while still providing dual-sided force application.

The resilient backup die serves multiple functions simultaneously: it provides counter-force during forming, supports the workpiece, distributes stresses uniformly, and adapts to varying forming geometries. This multi-functionality eliminates the need for complex coordination systems required in traditional dual-sided rigid tool forming, as the resilient material inherently adjusts to maintain optimal forming conditions.