Purpose: This paper aims to introduce a new incremental sheet metal-forming process. By moving a hammering tool over a sheet of metal fixed in a frame, a three-dimensional workpiece can be produced without using any special die plate. Design/methodology/approach: This paper describes the exact procedure of the new process and the advantages in comparison with other flexible conventional and incremental forming processes. The hammering process in particular, will be considered with respect to material behavior and effects on the industrial robot. In addition, a special path generation for the incremental forming process and multiple robot tools with different drives constructed for the incremental forming process is shown. Findings: During the research it was discovered that complex geometries can be produced without any die plate and that a hammering tool with a mechanical eccentric should be used for the incremental forming process. Practical implications: As the forces on the handling equipment are very low compared with other forming processes, a common industrial robot can be used to move the hammering tool. Thus sheet metal parts can be produced with cost-effective equipment. Mainly, small and medium-sized enterprises can benefit from this new technology. Originality/value: The incremental forming process presented in this paper is patented by the Fraunhofer Institute for Manufacturing Engineering and Automation. It is the first time that sheet metal parts with a size of 300 x 300mm are formed by a hammering tool with 100 hits/s
ABSTRACT:A large research program of digital product process has been active (2008)(2009)(2010)(2011)(2012) in Finland. The goal of the program has been to increase customer orientation and productivity in company networks that design and deliver products, systems and services to global markets. For small and medium sized companies the developing of multitechnical products usually has to be done in a network of companies. This requires a lot of data transfer and integration between various computer systems. To improve these processes the research project "Developing the digital product process of multitechnical products to improve the designing and manufacturing of small series product" (Monidigi) has been started.The aim of the Monidigi research was to improve the design process by using solely digital product information that is handled by proper product lifecycle management systems. The product development is guided by the philosophy of the digital prototype that is tested in a virtual working environment. Products are modeled in 3D and developed by various simulations and analyses before real prototypes are made. This allows a flexible design process and coordinated change management. Digital product processes allow easy data transfer, collaborated engineering and modern manufacturing in a network of companies. Several examples and development possibilities and the state of the art in construction industry are introduced and evaluated.
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