Tool path generation for single point incremental forming using intelligent sequencing and multi-step mesh morphing techniques

Amar Kumar Behera*, Bert Lauwers, Joost R. Duflou

*Corresponding author for this work

Research output: Contribution to journalArticle

15 Citations (Scopus)


A new methodology of generating optimized tool paths for incremental sheet forming is proposed in this work. The objective is to make parts with improved accuracy. To enable this, a systematic, automated technique of creating intermediate shapes using a morph mapping strategy is developed. This strategy is based on starting with a shape different from the final shape, available as a triangulated STL model, and using step-wise incremental deformation to the original mesh to arrive at the final part shape. Further, optimized tool path generation requires intelligent sequencing of partial tool paths that may be applied specifically to certain features on the part. The sequencing procedure is discussed next and case studies showing the application of the integrated technique are illustrated. The accuracy of the formed parts significantly improves using this integrated technique. The maximum deviations are brought down to less than 1 mm, while average absolute deviations of less than 0.5 mm are recorded.

Original languageEnglish
Pages (from-to)517-532
Number of pages16
JournalInternational Journal of Material Forming
Issue number4
Early online date13 May 2014
Publication statusPublished - Sep 2015


  • Incremental forming
  • Intelligent sequencing
  • Mesh morphing
  • Optimal tool paths
  • STL

ASJC Scopus subject areas

  • Materials Science(all)

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