An Integrated Approach to Accurate Part Manufacture in Single Point Incremental Forming Using Feature Based Graph Topology

Abstract

Previous studies have shown that optimized tool paths based on behavior of individual features and feature interactions can be used to improve the accuracy of features in parts produced by single point incremental forming. These tool paths are generated with compensated CAD files of the part, which result from a prediction of deviations of individual features. However, in order to improve the accuracy of an entire part, it is important to systematically look at behavior of all the individual features and all feasible interactions between features. In this paper, the authors present a graph topology approach to integrating the effects of the behavior of all features present in a part. For any given part, a conceptual graph is constructed representing all the features and connecting them based on their spatial locations with conceptual relations. Next, all possible feature interactions based on the generated graph are analyzed, and the deviations due to the feasible interactions in an uncompensated test are predicted. Depending on the feature types and interactions present, a comprehensive strategy for accurate part manufacture is generated. This strategy may be composed of a selection of one or more complementary tool path strategies for compensating the anticipated deviations on the part. Case studies illustrating improvement in accuracy of parts produced by this technique are discussed next to justify the use of the graph based approach.