Robot-based incremental sheet forming – the tool path planning

Abstract

Abstract To achieve a 3D shape with certain degree of complexity from metal sheets that are flat in the beginning, especially for prototype development or small series production, that is also cost efficient by avoiding high-end dies or expensive tooling, the incremental sheet forming process can represent the ideal choice due to its flexibility, reduced forming forces and increased formability. The process is performed with a round tool that follows a predefined path to deform the flat metal sheet into its final shape. The proper selection of the toolpaths affects the productivity and the accuracy of each part. The process having to focus on forming each single point in increments. For cost-effective production, the incremental sheet forming process is performed by an industrial robot. This paper aims to showcase the superior kinematic potential of the robot for complex tool paths by means of simulation. Singularity issues and robot joints limitation is checked through DELMIA software platform. After the design, simulation, and generation of the tool path, the software code can be generated and also used to steer the robot.