A Novel Modification to the Incremental Forming Process, Part 1: Multi-directional Tooling

Abstract Incremental forming (IF) is a novel sheet material forming technique, which has the ability to eliminate the need for die sets. The IF method forms sheet material by use of a non-cutting tool, which gradually deforms the sheet material into the desired shape. In the following works, this research proposes a range of novel tool geometries that allows forming of the sheet material in multiple directions at a rapid rate, allowing for greater formability, improved surface finish, and reduced springback. Additionally, several tool features are proposed which achieve this forming motion. Part 1 of this research describes the design of the tooling, as well as variations that are possible with the tool's geometry. In part 2 of this research, the proposed forming method is validated.

[1]  Arnold Puzik.  Incremental Sheet Forming with a Robot System for an Industrial Application , 2008 .

[2]  Mehdi Vahdati,et al.  Investigation of the ultrasonic vibration effect in incremental sheet metal forming process , 2017 .

[3]  Horst Meier,et al.  Increasing the part accuracy in dieless robot-based incremental sheet metal forming , 2009 .

[4]  Jian Cao,et al.  Mechanism investigation of friction-related effects in single point incremental forming using a developed oblique roller-ball tool , 2014 .

[5]  Ghulam Hussain,et al.  The performance of flat end and hemispherical end tools in single-point incremental forming , 2010 .

[6]  N. Hayat,et al.  Guidelines for Tool-Size Selection for Single-Point Incremental Forming of an Aerospace Alloy , 2013 .

[7]  Rolf Dieter Schraft,et al.  Incremental sheet metal forming by industrial robots , 2005 .

[8]  Gai Pin Cai,et al.  Sheet Single Point Vibration Incremental Forming Process Simulation and Analysis of Process Parameters , 2012 .

[9]  A. Erman Tekkaya,et al.  Tooling concepts to speed up incremental sheet forming , 2010, Prod. Eng..

[10]  Saeid Amini,et al.  An investigation of conventional and ultrasonic-assisted incremental forming of annealed AA1050 sheet , 2017 .

[11]  L. Vihtonen,et al.  Comparing two robot assisted incremental forming methods: incremental forming by pressing and incremental hammering , 2008 .

[12]  Dieter Kreimeier,et al.  Robot-Based Incremental Sheet Metal Forming – Increasing the Geometrical Accuracy of Complex Parts , 2011 .

[13]  J. J. Park,et al.  Effect of process parameters on formability in incremental forming of sheet metal , 2002 .

[14]  Paul A. Meehan,et al.  Simulation and Experimental Observations of Effect of Different Contact Interfaces on the Incremental Sheet Forming Process , 2014 .