Evaluation of the dimensional accuracy through 3D optical scanning in incremental sheet forming

Abstract

The aim of this study is to evaluate the dimensional accuracy of a truncated cone geometry obtained by single point incremental forming (SPIF). Due to the occurrence of defects causing the limitations of the incremental sheet forming process (ISF), strategies must be developed to overcome those limitations. For the purpose of this study, the industrial robot KUKA KR210 was selected as the process execution equipment due to high flexibility granted by the large number of degrees of freedom. The DC04 mild steel, widely used in automotive and numerous applications for its high formability properties, was the go-to material for the experimental investigations. The helical toolpath was chosen over the z-level contouring toolpath due to the fact that the punch is gradually deforming the metal blank for the entire length of the part’s depth growth, therefore being able to eliminate the disadvantages associated to the discontinuous character of the z-level contouring toolpath. To form the truncated cone shaped parts, the following parameters were varied: incremental step size of 0.5 mm or 1 mm, wall angle 50° or 60°. Within this paper, geometric accuracy is being evaluated and results show that geometrical deviation is influenced by wall angle, followed by incremental step.