Robotic Incremental Sheet Metal Forming: Waste Management Through Digital Fabrication

Abstract

In this investigation, a robotic incremental sheet forming (RISF) process was used as a response to traditional methods of recycling and reusing scrap metal. The methodology was carried out in three stages: digital reconstruction of the waste by 3D scanning, tensile test according to the ASTM E8 standard for the mechanical characterization of the material and the use of a heavy-load robot, KUKA KR180 R2500, for incremental forming. The results obtained in the tensile test indicated that the material maintains its isotropy and reaches 10% elongation. On the other hand, parameters of the incremental forming process showed: the ability of the material to be deformed with a maximum wall angle of 55°; speed rate of 50%; stepdown of 2 mm; and maximum depth of 75 mm. Finally, the process was used for the development of an ornamental surface.