Robot-based incremental sheet forming – the tool path planning

Abstract

To achieve a 3D shape with certain degree of complexity from metal sheets that are flat in the beginning, especially for prototype development or small series production, that is also cost efficient by avoiding high-end dies or expensive tooling, the incremental sheet forming process can represent the ideal choice due to its flexibility, reduced forming forces and increased formability. The process is performed with a round tool that follows a predefined path to deform the flat metal sheet into its final shape. The proper selection of the toolpaths affects the productivity and the accuracy of each part. The process having to focus on forming each single point in increments. For cost-effective production, the incremental sheet forming process is performed by an industrial robot. This paper aims to showcase the superior kinematic potential of the robot for complex tool paths by means of simulation. Singularity issues and robot joints limitation is checked through DELMIA software platform. After the design, simulation, and generation of the tool path, the software code can be generated and also used to steer the robot.

The incremental sheet forming; technology, modeling and formability: A brief review

“…Especially since these softwares are compatible with postprocessors of the different CNC machines used in ISF applications. Available CAM softwares (such as MasterCam, CATIA, CamWorks, etc) present strategies such as the z-level and spiral trajectories plotted respectively in Figure 20, 94 which can be used for the two parts frequently studied the cone and the truncated pyramid. Azaouzi and Lebaal 95 presented an optimization procedure tested for a given forming strategy, in order to reduce the manufacturing time and the homogenization of the thickness distribution of axisymmetric part.…”

Incremental forming using KUKA KR210-2 industrial robot - research regarding design rules and process modelling

“…The most important KUKA KR210-2 characteristics are presented in table 1. Due to ongoing development of robotic controllers and CAD/CAM software solutions, the industrial robots can be considered as a very suitable technological choice to process operations where continuous path control is essential [24].…”