Abstract
Incremental sheet metal forming can manufacture various sheet metal products without a dedicated punch and die set. In this study, we developed a two-stage incremental forming process to decrease shape errors in the conventional incremental forming process. The forming process was classified into the first single point incremental forming (1st SPIF) process for forming a product and the counter single point incremental forming (counter SPIF) process to decrease shape error. The counter SPIF gives bending deformation in the opposite direction. Furthermore, the counter SPIF compensates for shape errors, such as section deflection, skirt spring-back, final forming height, and round. The tool path of the counter SPIF has been optimized through a relatively simple optimization method by modifying the tool path of the previous step. The tool path of the 1st SPIF depends on the geometry of the product. An experiment was performed to form a circular cup shape to verify the proposed tool path of the 1st and counter SPIF. The result confirmed that the shape error decreased when compared to the conventional SPIF. For the application, the ship-hull geometry was adopted. Experimental results demonstrated the feasibility of the two-stage incremental forming process.
Highlights
In order to meet the customer’s various needs, a flexible manufacturing system, which includes flexibility for small batch production [1], is increasing
We proposed a procedure to construct the tool path for counter studied the effects of theerror
In Two-point incremental forming (TPIF), the full die, which has the same geometry as the target shape, to reduce shape errors
Summary
In order to meet the customer’s various needs, a flexible manufacturing system, which includes flexibility for small batch production [1], is increasing. Incremental sheet metal forming is a suitable forming technology for the aforementioned types of flexible manufacturing systems [2]. This corresponds to forming technology that produces the desired shape by increasing small deformations in contact with the tool and sheet. The incremental forming technology uses only a three-dimensional tool path and a simple forming tool on a CNC machine. Typical sheet metal forming requires the production of a die and punch. The incremental forming employs a round tool and tool path, as shown, instead of a die-set. The formability exceeds that of a typical forming technology, and various products can be manufactured [4]
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