Tool path generation framework for accurate manufacture of complex 3D sheet metal parts using single point incremental forming

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

*Corresponding author for this work

Research output: Contribution to journalArticle

30 Citations (Scopus)

Abstract

The prototyping of complex sheet metal parts using single point incremental forming (SPIF) requires the generation of optimal tool paths and/or tool path sequences that ensure that the formed part is within geometric design specifications. The presence of a multitude of features on complex parts leads to multiple inaccuracy inducing phenomena occurring simultaneously due to interactions between the features. This paper proposes a network analysis methodology using topological conceptual graphs to capture the effects of different phenomena on the final accuracy of a sheet metal part manufactured by SPIF. Using this framework optimized tool paths can be generated that compensate for the inaccuracy inducing behavior. Tool path generation algorithms to create partial tool paths that account for the accuracy of specific features in the part based on the proposed framework are also presented. Finally, the creation of integrated tool paths maintaining complementarity between tool paths and desired continuity behavior using non-uniform cubic B-splines is illustrated. A number of case studies demonstrating the applicability of the integrated framework are discussed, where the maximum deviations in the part are significantly reduced and the average absolute deviations for the complete part are brought down to less than 0.5 mm.

Original languageEnglish
Pages (from-to)563-584
Number of pages22
JournalComputers in Industry
Volume65
Issue number4
Early online date04 Feb 2014
DOIs
Publication statusPublished - May 2014

Keywords

  • Accuracy
  • Continuous tool paths
  • Graph topology
  • Partial tool paths
  • Single point incremental forming
  • Tool path generation

ASJC Scopus subject areas

  • Computer Science(all)
  • Engineering(all)

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