Experimental and numerical study of a milling machine-based dieless incremental sheet forming

In this paper, some relevant issues concerning an innovative sheet metal forming method, a milling machine-based Dieless Incremental Sheet Forming (DSF) will be analyzed. The experimental setup is based on the replacement of the commonly used dies by a second forming (Slave) tool where the movement is synchronized with the first forming (Master) tool, thus creating a flexible support. DSF can be used on both CNC machines [1] and industrial robots [2]. In this paper, the authors are only focusing on the experiments with a parallel kinematics 3-axis milling (PKM) machine with 3 additional linear actuators. The deformation state of the formed part will be analyzed using the Vialux-AutoGrid optical strain measurement system and will be compared to the results of 3D FEM modelling.