On the increase of geometric accuracy with the help of stiffening elements for robot-based incremental sheet metal forming

Thyssen, Lars; Seim, Patrick; Störkle, Denis Daniel; Kuhlenkoetter, Bernd

doi:10.1063/1.4963461

Cited by 6 publications

(3 citation statements)

References 10 publications

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“…Many of these methods embrace alterations of the geometrical input for the process, just as our method does. For instance, they advocate the creation of addendum surfaces [44] and extracurricular support structures [45], input geometry splitting and varying toolpath designs to enable multi-pass forming [46], as well as input geometry alteration [47,48]. However, what makes all those methods fundamentally different from our approach is their goal.…”

Section: Research Results In a Broader Contextmentioning

confidence: 99%

From Undesired Flaws to Esthetic Assets: A Digital Framework Enabling Artistic Explorations of Erroneous Geometric Features of Robotically Formed Molds

Zboinska

2019

Technologies

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Until recently, digital fabrication research in architecture has aimed to eliminate manufacturing errors. However, a novel notion has just been established—intentional computational infidelity. Inspired by this notion, we set out to develop means than can transform the errors in fabrication from an undesired complication to a creative opportunity. We carried out design experiment-based investigations, which culminated in the construction of a framework enabling fundamental artistic explorations of erroneous geometric features of robotically formed molds. The framework consists of digital processes, assisting in the explorations of mold errors, and physical processes, enabling the inclusion of physical feedback in digital explorations. Other complementary elements embrace an implementation workflow, an enabling digital toolset and a visual script demonstrating how imprecise artistic explorations can be included within the computational environment. Our framework application suggests that the exploration of geometrical errors aids the emergence of unprecedented design features that would not have arisen if error elimination were the ultimate design goal. Our conclusion is that welcoming error into the design process can reinstate the role of art, craft, and material agency therein. This can guide the practice and research of architectural computing onto a new territory of esthetic and material innovation.

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Section: Research Results In a Broader Contextmentioning

confidence: 99%

From Undesired Flaws to Esthetic Assets: A Digital Framework Enabling Artistic Explorations of Erroneous Geometric Features of Robotically Formed Molds

Zboinska

2019

Technologies

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“…While a small number of hybrid alternatives such stretch forming combined with SPIF have been explored, complex hybrid processes forming part of multitechnology platforms can be envisaged for the future. It is particularly important to extend the applicability of new tooling approaches such as stiffening elements [183] and develop generic error correction functions that extend to large sized parts and can be tuned as per the machine stiffness, to improve accuracy of formed parts. It may be noted that tooling based alternative process variants such as double sided incremental forming (DSIF) using two tools have shown the promise to improve a number of limitations of SPIF.…”

Section: Future Research Topics Roadmap and Summarymentioning

confidence: 99%

Single point incremental forming: An assessment of the progress and technology trends from 2005 to 2015

Behera

Sousa

Ingarao

et al. 2017

Journal of Manufacturing Processes

225

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The last decade has seen considerable interest in flexible forming processes. Among the upcoming flexible forming techniques, one that has captured a lot of interest is Single Point Incremental Forming (SPIF), where a flat sheet is incrementally deformed into a desired shape by the action of a tool that follows a defined toolpath conforming to the final part geometry. Research on SPIF in the last ten years has focused on defining the limits of this process, understanding the deformation mechanics and material behavior and extending the process limits using various strategies. This paper captures the developments that have taken place over the last decade in academia and industry to highlight the current state of the art in this field. The use of different hardware platforms, forming mechanics, failure mechanism, estimation of forces, use of toolpath and tooling strategies, development of process planning tools, simulation of the process, aspects of sustainable manufacture and current and future applications are individually tracked to outline the current state of this process and provide a roadmap for future work on this process.

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“…Currently, the challenge of this technology is the low geometric accuracy caused by the sheet springback and low stiffness of the robots. Focus in robot-based ISF is mainly on tool path optimization for geometric accuracy improvement in recent years, like the work by Meier et al [104], Storkle et al [105] and Thyssen et al [106]. air heat-assisted ISF utilized by Ji et al [112], oil heat-assisted ISF designed by Galdos et al [113] and friction heat-assisted ISF developed by Otsu et al [114].…”

Section: Isf Variantsmentioning

confidence: 99%

Investigation of control strategies for fracture prevention in the multi-point incremental sheet forming process

Wang¹

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This thesis is focused on understanding the deformation and failure mechanisms in incremental sheet forming (ISF) and on development of effective and efficient closed-loop control strategies to delay the fracture in multi-point ISF. Incremental sheet forming is a flexible and energy-efficient rapid prototyping process for production of small-batch and customized functional sheet components. The innovation of ISF is to achieve higher formability, flexibility and process control with localized plastic deformation compared with traditional sheet metal forming processes. Multi-point incremental forming (MPIF) shows higher formability and geometric accuracy than single point incremental forming (SPIF) and has attracted interest from industry currently. In the past decades, the industry application of multi-point ISF is still limited due to the limitation of formability, especially for producing parts with complex geometric features. Experimental and numerical ISF studies show that the formability in ISF can be improved by altering some critical process parameters. However, most of the proposed methodologies are either component specific or are based on trial-and-error approaches, while limited work has been published on closed-loop feedback control strategies for formability improvement in multi-point ISF. The first research objective of this thesis is the deformation mechanism and formability investigation in multi-point ISF. The aim of this study is to identify the contribution of different deformation modes and lay a foundation of developing damage model-coupled numerical simulation for fracture prediction in multi-point ISF. To this end, a full-scale three-dimensional numerical simulation with solid finite elements is developed. The deformation modes in different layers at different contact zones along different directions are investigated and discussed in detail. It is indicated that the existence of the supporting die leads to an increase of the hydrostatic pressure and the through-thethickness shear strain, and a decrease of the stress gradient in the thickness direction in the doublesided contact zone, which may lead to smaller springback and slow the damage accumulation rate in multi-point ISF. The second objective of this thesis is focused on the fracture prediction in multi-point ISF. In particular, six damage models are coded into finite element models through ABAQUS/VUMAT subroutine and a numerical comparative study is conducted for fracture prediction in multi-point ISF with a free-formed ellipsoid shape under different loading conditions. It is indicated that the Ayada model could predict the fracture location and fracture depth more accurately than others, however, it is also found that the fracture location and fracture depth cannot be accurately predicted simultaneously with the investigated damage models in this study. In addition, it can be found that Publications included in this thesis No publications included.

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On the increase of geometric accuracy with the help of stiffening elements for robot-based incremental sheet metal forming

Cited by 6 publications

References 10 publications

From Undesired Flaws to Esthetic Assets: A Digital Framework Enabling Artistic Explorations of Erroneous Geometric Features of Robotically Formed Molds

From Undesired Flaws to Esthetic Assets: A Digital Framework Enabling Artistic Explorations of Erroneous Geometric Features of Robotically Formed Molds

Single point incremental forming: An assessment of the progress and technology trends from 2005 to 2015

Investigation of control strategies for fracture prevention in the multi-point incremental sheet forming process

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