Spring-Biased Forming Tool for Accurate Double-Sided Sheet Forming
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional double-sided incremental forming tools face challenges in maintaining accurate contact with workpieces due to errors in simulation, machine stiffness variations, and mismatched sheet thickness, leading to damage and reduced accuracy in the forming process.
Innovation Solution
A forming tool design featuring a sleeve with a hollow interior, a spring-biased contact member, and bearing members that allow for rotational and translational movement, ensuring the working tip remains in contact with the workpiece by accommodating misalignment and providing necessary stiffness without causing material deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional tools use displacement control to clamp and move forming and support tools together, then the workpiece is deformed to achieve desired shape, but the material is squeezed and stretched in- and out- of plane causing damage and lack of accuracy
Solution Approach 1:
The invention changes the control parameter from displacement control to force control. The support tool is equipped with a spring mechanism that applies a constant normal force to the workpiece, allowing the workpiece to deform naturally under the forming tool without being squeezed and stretched, thereby preventing material damage while maintaining forming accuracy
Solution Approach 2:
The invention introduces a dynamic spring mechanism that allows the support tool to adapt to workpiece thickness variations and deformation. The spring automatically adjusts the support position and force, enabling the system to respond dynamically to changing workpiece geometry without causing material damage
2Ease of manufacture
If simulation assumptions are made during double sided incremental forming, then the process can be planned, but errors arise from variation in machine stiffness, mismatched sheet thickness, and other factors leading to loss of contact
Solution Approach 1:
The support tool with spring mechanism is self-adjusting and does not require precise pre-programming of contact forces. The spring automatically compensates for thickness variations and machine stiffness changes, making the system self-adapting to real-world variations without relying on accurate simulation assumptions
Solution Approach 2:
The spring mechanism provides continuous mechanical feedback through its compression and extension, automatically adjusting the support force based on actual workpiece conditions. This real-time mechanical feedback compensates for deviations from simulation predictions, maintaining reliable contact without requiring complex sensing or control systems
3Manufacturing precision
If the support tool and workpiece contact is lost due to errors in simulation and machine variation, then the forming process cannot proceed accurately, but increasing clamping force causes material damage
Solution Approach 1:
The invention changes from displacement control to force control, applying a constant normal force through the spring mechanism. This ensures continuous contact without requiring high clamping forces, preventing material damage while maintaining forming accuracy through force-based rather than position-based 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
The tool effectively maintains contact with the workpiece during the forming process, reducing damage and improving accuracy by accommodating misalignment and stiffness variations, thus enhancing the quality of the finished part.
Implementation Method 1
A spring is positioned within hollow interior space of the sleeve. The contact member is biased outward away from the sleeve by the spring.
Implementation Method 2
Bearing members act on the contact member and provide for rotational and translational movement of the contact member relative to the mount.
Data Source
AI summary
A tool for use during double sided incremental forming of a workpiece. The tool includes a sleeve with a hollow interior space. A contact member is positioned within the hollow interior space of the sleeve. The contact member is sized with a working tip positioned outward beyond the sleeve to contact against a workpiece. A mount is positioned on the opposing end of the sleeve and configured to connect to a tool holder. The tool is configured to provide for translational and/or rotational movement of the contact member. The axial and rotational movement provides for the working tip to remain in contact with the workpiece during the forming process.