Driving – A Flexible Manufacturing Method for Individualized Sheet Metal Products

2010 ◽  
Vol 447-448 ◽  
pp. 795-800
Author(s):  
Daniel Scherer ◽  
Z. Yang ◽  
H. Hoffmann
Keyword(s):  
Production Process ◽  
Sheet Metal ◽  
Flexible Manufacturing ◽  
Incremental Forming ◽  
Industrial Robot ◽  
General Information ◽  
Work Piece ◽  
Forming Process ◽  
Manufacturing Method ◽  
Metal Products

This paper provides general information about the qualification of driving as an on-demand manufacturing concept for the production of individualized sheet metal products. Driving allows the creation of almost any 2D or 3D geometry, but it is a highly interactive, manual production process. Due to the inevitable variations of the incremental forming process (mechanical properties, tribology, wear etc.) and the high number of forming steps, it cannot be automated by traditional approaches. At the Institute of Metal Forming and Casting (Technische Universitaet Muenchen) a kraftformer machine has been equipped with measuring and controlling instrumentation. An optical online measurement system is installed to detect any geometry deformation of the current work piece and to visualize the deviation between the actual and the stored reference geometry during the whole production process. This variance comparison is the first step for planning any following incremental forming actions based on acquired and/or learned knowledge. The second step is the integration of an industrial robot for work piece handling and the automation of the whole manufacturing process. The last step is the integration of neural networks to predict production strategies for any desired unique geometry.

Robot-Forming - An Incremental Forming Process Using an Industrial Robot by Means of DELMIA Software Package

2013 ◽  
Vol 371 ◽  
pp. 416-420 ◽  
Author(s):  
Ionut Chera ◽  
Octavian Bologa ◽  
Sever Gabriel Racz ◽  
Radu Eugen Breaz
Keyword(s):  
Sheet Metal ◽  
Software Package ◽  
Incremental Forming ◽  
Industrial Robot ◽  
Metal Part ◽  
Forming Process ◽  
Program Code ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Custom Made

The purpose of this research is to present an alternative method for manufacturing sheet metal parts using an asymmetric incremental forming process by means of an industrial robot. This method is based on designing, simulating and generating the toolpath for the tool attached to the robot using DELMIA software package. The proposed approach allows users to check for system collisions, robot joins limitations and singularity problems. After a comprehensive simulation of the movements of the robot is performed, the program code can be generated by means of a specific DELMIA function. The program can be used afterwards to control the robot during the experimental work. In order to demonstrate the capabilities of robot-forming, a truncated pyramid sheet metal part was manufactured using a custom made stand and with the help of a KUKA KR6 anthropomorphic robot.

Geometrical Modeling of the Sheet Metal Parts in the Incremental Shrinking Process

2011 ◽  
Vol 473 ◽  
pp. 509-515 ◽  
Author(s):  
Zong Ru Yang ◽  
Daniel Scherer ◽  
Matthias Golle ◽  
Hartmut Hoffmann
Keyword(s):  
Sheet Metal ◽  
Geometric Model ◽  
General Information ◽  
Metal Sheet ◽  
Forming Process ◽  
Software Environment ◽  
Manufacturing Method ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Shrinking Process

Shrinking is an incremental forming process and can be carried out using a driving machine, so called “Kraftformer”. It needs an upper and a lower shrinking tool, each of which has two moveable jaws as contact and force transform units. During every forming operation the tools clamp the metal sheet, so that the vertical forces from the upper tool are switched by the leverages inside the tools into the horizontal directions. The moveable jaws are practiced by the horizontal forces to compress the metal sheet. The shrinking of the metal sheet brings out the different three-dimensional forms. As a traditional manual forming method, economical productions can’t be reached for individualized sheet metal parts to achieve the customer’s demands. Hence, it is proposed to automate this forming process to reduce the manual work. The production strategies are to be deduced from the manual shrinking process. A direct way to get them is to simulate the forming process in a FEM-software environment. But within such a FEM-simulation it can take about even one hour only just to finish one forming step. Furthermore, an analytical modeling of the shrinking can’t be realized because of its complex procedures such as variation of contact conditions, material hardening. However, a pure geometric model can be established to demonstrate the change of the 3D-forms of the sheet metal parts. The respective forming parameters can be identified through the experiments. The simulation can take place only in a few seconds. This paper provides general information about the application of the manufacturing method and with it the qualification of shrinking as a manufacturing concept for the production of individualized sheet metal products.

Studies for the Development of a Simulation Basis for Numerically Controlled Driving of Sheet Metal

2005 ◽  
Vol 6-8 ◽  
pp. 517-524 ◽  
Author(s):  
Hartmut Hoffmann ◽  
R. Hautmann ◽  
R. Petry
Keyword(s):  
Production Process ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Sheet Steel ◽  
Ancient World ◽  
Work Piece ◽  
Forming Process ◽  
Production Processes ◽  
Steel Angles

The manufacturing technique of driving is one of the oldest procedures for sheet metal forming and has been used in the ancient world for the production of copper pots and vases. This technique is still utilized for niche applications but today has lost its importance. The process of driving is almost completely carried out manually and thus is only appropriate for very small quantities or in case of failure of other production processes. Since individualization of products is strongly gaining in significance, forming processes have to be found, which are independent from expensive tools and equipment. Using driving as the process of choice to form sheet metal, the grade of automation of the forming process has to be increased. Numerically controlled driving, i.e. automated positioning and handling of the work piece during the production process, will need a conclusive simulation base. This paper provides results of the analysis of sheet steel angles formed by the driving sub groups of shrinking and stretching.

Comparison between an Advanced Numerical Simulation of Sheet Incremental Forming Using Adaptive Remeshing and Experimental Results

2013 ◽  
Vol 554-557 ◽  
pp. 1375-1381 ◽  
Author(s):  
Laurence Giraud-Moreau ◽  
Abel Cherouat ◽  
Jie Zhang ◽  
Houman Borouchaki
Keyword(s):  
Numerical Simulation ◽  
Numerical Model ◽  
Sheet Metal ◽  
Metal Forming ◽  
Tool Path ◽  
Incremental Forming ◽  
Computation Time ◽  
Experimental Results ◽  
Forming Process ◽  
Adaptive Remeshing

Recently, new sheet metal forming technique, incremental forming has been introduced. It is based on using a single spherical tool, which is moved along CNC controlled tool path. During the incremental forming process, the sheet blank is fixed in sheet holder. The tool follows a certain tool path and progressively deforms the sheet. Nowadays, numerical simulations of metal forming are widely used by industry to predict the geometry of the part, stresses and strain during the forming process. Because incremental forming is a dieless process, it is perfectly suited for prototyping and small volume production [1, 2]. On the other hand, this process is very slow and therefore it can only be used when a slow series production is required. As the sheet incremental forming process is an emerging process which has a high industrial interest, scientific efforts are required in order to optimize the process and to increase the knowledge of this process through experimental studies and the development of accurate simulation models. In this paper, a comparison between numerical simulation and experimental results is realized in order to assess the suitability of the numerical model. The experimental investigation is realized using a three-axis CNC milling machine. The forming tool consists in a cylindrical rotating punch with a hemispherical head. A subroutine has been developed to describe the tool path from CAM procedure. A numerical model has been developed to simulate the sheet incremental forming process. The finite element code Abaqus explicit has been used. The simulation of the incremental forming process stays a complex task and the computation time is often prohibitive for many reasons. During this simulation, the blank is deformed by a sequence of small increments that requires many numerical increments to be performed. Moreover, the size of the tool diameter is generally very small compared to the size of the metal sheet and thus the contact zone between the tool and the sheet is limited. As the tool deforms almost every part of the sheet, small elements are required everywhere in the sheet resulting in a very high computation time. In this paper, an adaptive remeshing method has been used to simulate the incremental forming process. This strategy, based on adaptive refinement and coarsening procedures avoids having an initially fine mesh, resulting in an enormous computing time. Experiments have been carried out using aluminum alloy sheets. The final geometrical shape and the thickness profile have been measured and compared with the numerical results. These measurements have allowed validating the proposed numerical model. References [1] M. Yamashita, M. Grotoh, S.-Y. Atsumi, Numerical simulation of incremental forming of sheet metal, J. Processing Technology, No. 199 (2008), p. 163 172. [2] C. Henrard, A.M. Hbraken, A. Szekeres, J.R. Duflou, S. He, P. Van Houtte, Comparison of FEM Simulations for the Incremental Forming Process, Advanced Materials Research, 6-8 (2005), p. 533-542.

Stress Analysis of Sheet Metal Vibration Incremental Forming

2010 ◽  
Vol 154-155 ◽  
pp. 166-170
Author(s):  
Gai Pin Cai ◽  
Ning Yuan Zhu ◽  
Na Wen
Keyword(s):  
Sheet Metal ◽  
Incremental Forming ◽  
Low Frequency ◽  
Forming Process ◽  
Technical Parameters ◽  
Vibration Technique ◽  
Low Frequency Vibration ◽  
Metal Deformation ◽  
Angle Effect ◽  
Forming Angle

As a non-homogenous force stresses during incremental forming, sheet metal easily tended to instability, and some defects, such as deposition, wrinkle and fracture, would appear. If the vibration technique was combined the incremental forming process, its deformation mechanism would be different from that of the old process, and sheet metal deformation quality was also risen. Then some mechanical equations were built by force analyzed on element in local contact zone of die head forcing down. According to reasonable hypothesis and simplified, the equations were solved. Some stress-time curves of the element were obtained by given process parameters, vibrational parameters and time parameters. It is shown from analysis that stress variety of the element is closely related to amplitude, frequency and forming angle, effect of sheet metal vibration incremental forming with high frequency vibration is more superior than that of with low frequency vibration; only when vibrational parameters are reasonably matching technical parameters, the effective vibration incremental forming can be obtained.

Effects of Tool Deflection in Accumulated Double-Sided Incremental Forming Regarding Part Geometry

2016 ◽  
Author(s):  
Huaqing Ren ◽  
Newell Moser ◽  
Zixuan Zhang ◽  
Kornel F. Ehmann ◽  
Jian Cao
Keyword(s):  
Sheet Metal ◽  
Relative Position ◽  
Capital Investment ◽  
Incremental Forming ◽  
Position Angle ◽  
Tool Deflection ◽  
Geometric Accuracy ◽  
Localized Deformation ◽  
Forming Process ◽  
Part Geometry

Incremental forming is a flexible dieless forming process. In incremental forming, the metal sheet is clamped around its periphery. One or multiple generic stylus-type tools move along a predefined toolpath, incrementally deforming the sheet metal into a final, freeform shape. Compared with the traditional sheet metal forming process, the incremental forming process is more flexible, energy efficient and cost effective due to lower capital investment related to tooling. However, maintaining tight geometric tolerances in incremental formed parts can be a challenge. Specifically, undesired global bending is usually induced near the region between the tools and fixture resulting in a compromise in geometric accuracy. To address this issue, Accumulated Double-Sided Incremental Forming (ADSIF) is proposed, which utilizes two tools on both sides of the metal to better achieve localized deformation while simultaneously constraining global bending outside the forming area. Moreover, in ADSIF, the two tools are moving from inward to outward, and thus the tools are always forming virgin material and so as to limit forces on the already-formed part. Thus, ADSIF has a higher potential to achieve the desired geometry. Nevertheless, tool deflection due to machine compliance is still an issue that can have a considerable effect on geometric accuracy. In this work, the effect of tool deflection related to part geometry is studied for the ADSIF process. The nature of using two tools, rather than one, in ADSIF inherently implies that relative tool position is a critical process parameter. It is the region near these two tools where local squeezing and bending of the sheet occurs, the primary modes of deformation found in ADSIF. The change of relative tool positions (i.e., tool gap and relative position angle) are studied in detail by first developing an analytical model. It is concluded that the tool gap will be enlarged under the influence of tool compliance while the relative position angle is less affected. Additionally, a finite element simulation capable of modeling tool deflection is established. The comparison between the simulation results using rigid tools and deformable ones clearly demonstrated the significant influence of tool compliance on part geometry. Lastly, an axisymmetric part with varying wall angles was formed, and it was confirmed that ADSIF demonstrates improved geometry accuracy compared with conventional Double-Sided Incremental Forming.

Finite Element Analysis of Incremental Sheet Forming for Metal Sheet

2018 ◽  
Vol 783 ◽  
pp. 148-153
Author(s):  
Muhammad Sajjad ◽  
Jithin Ambarayil Joy ◽  
Dong Won Jung
Keyword(s):  
Mechanical Properties ◽  
Sheet Metal ◽  
Tool Path ◽  
Incremental Forming ◽  
Single Point ◽  
Machining Process ◽  
Machining Parameters ◽  
Forming Process ◽  
Element Analysis ◽  
Tool Diameter

Incremental sheet metal forming, is a non-conventional machining process which offers higher formability, flexibility and low cost of production than the traditional conventional forming process. Punch or tool used in this forming process consecutively forces the sheet to deform locally and ultimately gives the target profile. Various machining parameters, such as type of tool, tool path, tool size, feed rate and mechanical properties of sheet metal, like strength co-efficient, strain hardening index and ultimate tensile strength, effects the forming process and the formability of final product. In this research paper, Single Point Incremental Forming was simulated using Dassault system’s Abaqus 6.12-1 and results are obtained. Results of sheet profile and there change in thickness is investigated. For this paper, we simulated the process in abaqus. The tool diameter and rotational speed is find out for the production of parts through incremental forming. The simulation is done for two type of material with different mechanical properties. Various research papers were used to understand the process of incremental forming and its simulation.

scholarly journals Common defects of parts manufactured through single point incremental forming

2021 ◽  
Vol 343 ◽  
pp. 04007
Author(s):  
Mihai Popp ◽  
Gabriela Rusu ◽  
Sever-Gabriel Racz ◽  
Valentin Oleksik
Keyword(s):  
Sheet Metal ◽  
Metal Forming ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Metal Forming Process ◽  
Serial Robot ◽  
The Many ◽  
Cold Metal

Single point incremental forming is one of the most intensely researched die-less manufacturing process. This process implies the usage of a CNC equipment or a serial robot which deforms a sheet metal with the help of a relatively simple tool that follows an imposed toolpath. As every cold metal forming process, besides the many given advantages it has also some drawbacks. One big drawback in comparison with other cold metal forming processes is the low accuracy of the deformed parts. The aim of this research is to investigate the sheet metal bending mechanism through finite element method analysis. The results shows that the shape of the retaining rings has a big influence over the final geometrical accuracy of the parts manufactured through single point incremental forming.

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