Tool Path Generation for Single Point Incremental Forming Using Intelligent Sequencing and Multi-Step Mesh Morphing Techniques

Abstract

A new methodology of generating optimized tool paths for incremental sheet forming is proposed in this work. The objective is to make parts with improved accuracy. To enable this, a systematic technique of creating features using a morph mapping strategy is developed. This strategy is based on starting with a shape different from the final shape, available as a triangulated STL model, and using step-wise incremental deformation to the original mesh to arrive at the final part shape. Further, optimal tool path generation requires intelligent sequencing of partial tool paths that may be applied specifically to certain features on the part. The sequencing procedure is discussed next and a case study showing the application of the integrated technique is illustrated.