FlexDie: A Flexible Tooling-Concept for Incremental Sheet Forming

Abstract:

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.

• Periodical: Key Engineering Materials (Volumes 504-506)
• Pages: 883-888
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.504-506.883
• Online since: February 2012
• Authors: Gerd Sebastiani, Arthur Wawrosch, Volker Franzen, Alexander Brosius, A. Erman Tekkaya
• Keywords: Asymmetric Incremental Sheet Forming, Case Study, Rapid Tooling, Two Point Incremental Forming

References

[1] G. Sebastiani, V. Franzen, K. Roll, A. Brosius and A. E. Tekkaya, German Patent Application 102010033399. (2010)

[2] J. Jeswiet , J. R. Duflou, A. Szekeres, P. Lefebvre, Custom Manufacture of a Solar Cooker – A Case Study, AMR, 6-8, (2005) 487–492.

DOI: 10.4028/www.scientific.net/amr.6-8.487

[3] H. Iseki, K. Kato, S. Sakamoto, Forming Limit of Flexible and Incremental Sheet Metal Bulging with a Spherical Roller, Proc. 4th ICTP, 3, (1993) 1635-1640.

[4] J. Jeswiet, F. Micari, G. Hirt, A. Bramley, J. Duflou, J. Allwood, Asymmetric single point incremental forming of sheet metal, Ann. CIRP, 54, (2005) 623-650.

DOI: 10.1016/s0007-8506(07)60021-3

[5] L. Lamminen, Incremental Sheet Forming with an Industrial Robot – Forming Limits and Their Effect on Component Design, Proc 11th SHEMET, (2005) 457-465.

[6] Derde Wereld Werkplaats, The solar cooker, http://www.dwwbreda.org

[7] R. Shankar, Surface Reconstruction and Tool Path Strategies for Incremental Sheet Metal Forming, Institut für Umformtechnik und Leichtbau, Universität Dortmund, Diss., 2008.

[8] G. Hirt, S. Junk, N. Witulski, Surface Quality, Geometry Precision and Sheet Thinning in Incremental Sheet Forrning, Proc. Material Week, (2001) Paper No. 442G3.

[9] G. Hirt, J. Ames, M. Bambach, Basic investigation into the characteristics of dies and support tools used in CNC incremental sheet forming, Proc. IDDRG, (2006) 341–348.

[10] M. Bambach, B. Taleb Araghi, G. Hirt, Strategies to improve the geometric accuracy in asymmetric single point incremental forming, Proc. Eng. Res, Devel., 3, (2009) 145-156.

DOI: 10.1007/s11740-009-0150-8

[11] M. Durante, A. Formisano, A. Langella, Comparison between analytical and experimental roughness values of components created by incremental forming, JMPT, 14, (2010) 1934-1941

DOI: 10.1016/j.jmatprotec.2010.07.006

[12] K. Hamilton, J. Jeswiet, Visual Categorization and Quantification of the Orange Peel Effect in Single Point Incremental Forming at High Forming Speeds, Trans. NAMRI /SME, 38 (2010) 679-686.