On the increase of geometric accuracy with the help of stiffening elements for robot-based incremental sheet metal forming

摘要

This paper describes new developments in an incremental, robot-based sheet metal forming process (‘Roboforming’) for the production of sheet metal components for small lot sizes and prototypes. The incremental sheet forming (ISF) offers high geometrical form flexibility without the need of any part-dependent tools. To transfer the ISF to industrial applications, it is necessary to respond to the still existing constraints, e.g. the low geometrical accuracy. Especially the subsequent deformation resulting from the interaction of differently shaped elements causes geometrical deviations, which are limiting the scope of formable parts. The impact of the resulting forming forces will vary according to the shape of the individual elements. For this, the paper proposes and examines a new approach to stabilize the geometrical accuracy without losing the universal approach of Roboforming by inserting stiffening elements. Those elements with varying cross-sections at the initial area of various orientations must be examined on their stabilizing or subsequent distorting impact. Especially the different impacts of the subsequent forming of stiffness features in contrast to the direct forming are studied precisely.