FlexDie: A Flexible Tooling-Concept for Incremental Sheet Forming
Forming tasks in Sheet Metal Prototyping are currently a balancing act between part flexibility and accuracy. In view of Asymmetric Incremental Sheet Forming (AISF), the part support is the decisive factor: Die-based processes such as TPIF are restricted to the given geometry of the part. On the other hand, the die-less variant (SPIF) is prone to a much more complex process-layout – once a similar accuracy needs to be obtained. Consequently, this requires a flexible die concept, supporting the part in the critical zones only. Within this article we meet this challenge by introducing the configurable tooling concept "FlexDie". This support tool comprises a construction kit for skeleton dies allowing for an adjustment of its geometry to almost any desired shape. Based on the solar cooker benchmark by Jeswiet et al., we show both the tooling-concept and the feasibility. The latter we discuss, based on the quality features geometric accuracy as well as surface quality. Both features are assessed with respect to the forming results obtained by use of a full-die. The accuracy resulting by applying the FlexDie is only slightly inferior to the parts formed by use of a full-die. However, the FlexDie allows for simple optimization of both, die and part geometry. In addition, compensation strategies by adapting the toolpath are still possible. In summary, the results show the feasibility of the FlexDie concept for industrial ISF tasks - even at very low production volumes.