Accuracy improvement in single point incremental forming through systematic study of feature interactions

Previous studies have shown that feature detection and part segmentation are useful tools to generate compensated toolpaths for single point incremental forming leading to improvement in accuracy of manufactured parts. However, in most practical applications, features do not occur by themselves. Rather, they occur in combination with other features, and the presence of the neighbouring features influences the behaviour of the feature of interest. The final shape of the formed part depends on the interaction between the features. In this study, an attempt has been made to generate a complete taxonomy of common features relevant for incrementally formed parts. This taxonomy is then utilized to generate a matrix of feature interactions, and to classify them as feasible or not. From the subset of feasible feature interactions, a number of cases are analyzed to illustrate the effect of the interactions on the magnitude and nature of inaccuracies resulting in uncompensated parts. Strategies to use the knowledge of the interaction between these features to improve the accuracy of the manufactured parts are then discussed with the help of experimental case studies.