Papers by Author: V. Smukala

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Authors: D. Kreimeier, J. Zhu, V. Smukala, B. Buff, C. Magnus
Abstract: Robot based incremental sheet metal forming (Roboforming)is a new dieless forming process, which is suitable for cost-effective manufacture of prototype parts and small batch sizes.The principle of Roboforming is based on flexible shaping through a freely programmable path-synchronous movement of two industrial robots. These two robots, which are connected to a cooperating robot system, hold respectively a forming and a supporting tool. Similar to other incremental forming methods, the final shape is produced bythe movement of the forming toolalongthe lateral direction and its gradual infeed in the depth direction. In Roboforming, there are twodifferent strategies for the synchronous movement of the supporting tool, eitheralong the outer contour onbacksideof the sheet or directly opposed to the forming tool building a forming gap.The second strategy can be combined with a force controlled method to increase the surface quality and geometricaccuracy. MThe most existing CAM systems used in numerous incremental forming approaches are only applicable for milling machines. In this paper, with the use of self-programmed postprocessors and an Application Programming Interface (API) in a CAM system, movement programs for two cooperating robots can be generated for both forming strategies to produce sheet metal parts with different sizes and complex freeform structures. This CAM-solution for Roboforming is validated bythe forming experiments.
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Authors: D. Kreimeier, B. Buff, C. Magnus, V. Smukala, J. Zhu
Abstract: This paper describes new developments in an incremental, robot-based sheet metal forming process (Roboforming) for the cost-effective production of sheet metal components for limited-lot productions and prototypes. The paper presents strategies in robot based incremental sheet metal forming for the force controlled forming of complex parts. These parts can consist of features such as steep flanks or convex/concave alternating surfaces and they are mostly formed with a local support tool which substitutes a full die. The strategies were developed in a cooperative project funded by the German Federal Ministry of Education and Research and the German Research Foundation. Approaches to increase the part accuracy of complex parts are presented. One approach concentrates on a servo loop, consisting of sensors and a programming system. It guarantees higher part accuracies by measuring the deviations between a formed part and its target geometry. These deviations are used to derive corrected tool paths. The abdication of a partial or full die leads to a larger influence of the free compliant sheet area surrounding the formed part. Because of that the geometry shifts away from the forming tool and it cannot be formed completely. Another approach to increase the part accuracy by reinforcing this free sheet area is also presented.
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Authors: Horst Meier, B. Buff, V. Smukala
Abstract: This paper describes new developments in incremental, robot-based sheet metal forming (Roboforming). Roboforming is a dieless sheet metal forming process which ensures cost-effective manufacturing of prototype parts and small batches. An approach for increasing the part accuracy in Roboforming is presented. It is developed in a cooperative project funded by the German Federal Ministry of Education and Research called Roboforming. The project concentrates on the development of an industrial applicable system design. The use of standard components allows a modular and scalable set-up. A servo loop, consisting of sensors and a programming system, represents the basis of this design and shall guarantee higher part accuracies by measuring the deviations between a formed part and its target geometry. The deviations are used to derive corrected tool paths. The correction is performed by an adjustment vector for every point on the tool path. The theory for this strategy and first results are presented in this paper.
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Authors: Horst Meier, Jan Brüninghaus, B. Buff, Alfred Hypki, Adrian Schyja, V. Smukala
Abstract: This paper describes a new development in incremental, robot-based sheet metal forming (Roboforming). Roboforming is a dieless sheet metal forming process which ensures cost-effective manufacturing of prototype parts and small batches. Its principle is based on flexible shaping by means of a freely programmable path synchronous movement of two industrial robots driving work-piece independent forming tools. The final shape is produced by the incremental inward motion of the forming tool in depth direction and its movement along the contour in lateral direction on a heli-cal path. The supporting tool, with its simple geometry, holds the sheet on the backside by moving syn¬chronously along the outer contour, at constant depth. In this way no special dies are needed. For mil¬ling machines, which are used in numerous incremental forming approaches, CAD/CAM inter¬faces exist for generating necessary tool paths. For industrial robots only a few simple solutions emerge, which do not have the potential of classical CAD/CAM interfaces and are unusable for co-operating robot systems. While the two coupled robot programs can be programmed manually for simple geometries, this approach does not work for complex geometries. In this paper a further de-velopment in robot programming systems is presented that is now able to derive helical tool paths from any CAD file and generate two cooperating programs for the forming and the sup¬porting tools. The helixes pitch is variable and dependent on the geometry’s wall angle. To increase the part accu¬racy a process database is used, that stores relevant information about the process pa¬rameters, sensor data and used equipment. Based on this information strategies for increasing the part accuracy can be applied.
143
Authors: Horst Meier, V. Smukala, O. Dewald, Jian Zhang
Abstract: This paper describes a new development of an incremental, robot based sheet metal forming process for the production of sheet metal components for limited-lot productions and prototypes. The kinematic based generation of the shape is implemented by means of two industrial robots, which are interconnected to a cooperating robot system. Compared to other incremental sheet metal forming machines this system offers a high geometrical form flexibility without the need of any workpiece dependent tools. The principle of the procedure is based on flexible shaping by means of a freely programmable path-synchronous movement of two robots. So far, the final shape is produced by the incremental infeed of the forming tool in depth direction and its movement along the contour in lateral direction on each level. The counter tool, with its simple geometry, was used to support the sheet metal on the backside by moving synchronously along the outer contour, constantly on the same level. This corresponds to a fixed backplate used in other incremental sheet metal forming processes. Due to the use of a new robot system with extended control algorithms for cooperating robots, it will be possible to release the counter tool from its constant path on the outer contour and support the forming tool right on the opposite side of the sheet to generate a predefined gap between the two hemispherical tools. This way at each moment a small part of a full die, as it is used in other processes, is simulated without the need of producing a workpiece dependent die. The extended payload of the new robot system gives the opportunity to form steel blanks, for the first time.
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