SBIR Phase I: A Double Sided Incremental Forming System for Rapid Dieless Sheet Metal Fabrication

这个小型企业创新研究（SBIR）第一阶段项目将解决与创新的无模金属板成形工艺——双面增量成形（DSIF）商业化相关的关键技术挑战。DSIF局部变形的外围夹紧钣金组件使用一个小的半球形端刀在板材的两侧，每个移动沿着预定的刀具路径。目前的刀具轨迹生成方法没有考虑到成形过程中板料变形的力学特性，导致成形时间过高，几何精度不理想。这项研究将创建新的自动化刀具路径设计方法，该方法考虑了DSIF期间金属板的变形力学，以实现500 ìm或更低的零件精度，同时保持用户定义的吞吐量。此外，将设计一个新的DSIF成形中心，可以使用高强度合金形成大型部件，这需要高机器刚度和成形力。这项工作将为快速成型和小批量生产金属薄板零件的DSIF商业化提供重要的科学和技术基础。该项目的更广泛/商业潜力是通过消除昂贵的模具，显着降低快速成型和低批量制造高质量钣金部件的成本。将变形力学纳入DSIF刀具路径规划将在刀具路径与DSIF成形产品的最终几何形状和应力之间建立牢固的联系。因此，优化刀具路径生成的迭代实验过程将被一种结构化的、科学的和更健壮的刀具路径生成方法所取代。与传统成型相比，DSIF的优点包括不需要昂贵的特定形状模具（每个高达100万美元），更高的可成形性（高4倍）和更低的成形力（低30%）。DSIF具有更强的可成形性，可以实现轻量化，提高燃油效率，从而进一步节省能源。DSIF将消除存储传统模具的成本，因为重新制造零件只需要电子格式的零件模型。

This Small Business Innovation Research (SBIR) Phase I project will resolve key technical challenges associated with the commercialization of an innovative die-less sheet metal forming process, Double Sided Incremental Forming (DSIF). DSIF locally deforms a peripherally clamped sheet metal component using a small hemispherical ended tool on either side of the sheet, each moving along a pre-determined tool path. Current toolpath generation methodologies do not take into account the mechanics of sheet deformation during the forming process, resulting in unacceptably high forming time and unsatisfactory geometry accuracy. This research will create new automated toolpath design methodologies which account for the deformation mechanics of the sheet metal during DSIF to achieve part accuracies of 500 ìm or less while maintaining a user defined throughput. Additionally, a new DSIF forming center will be designed that can form large components using high strength alloys, where high machine stiffness and forming force are required. This work will provide a significant scientific and technological foundation towards commercializing DSIF for rapid prototyping and low volume production of sheet metal parts.The broader/ commercial potential of this project is to significantly reduce the cost of rapid prototyping and low volume fabrication of quality sheet metal components by eliminating the need for expensive die sets. The inclusion of deformation mechanics into DSIF toolpath planning will establish a strong connection between the toolpath and the final geometry and stresses of the formed product in DSIF. Consequently, the iterative experimental procedure for optimum toolpath generation will be replaced by a structured, scientific and more robust toolpath generation methodology. The advantages of DSIF as compared to conventional forming include absence of expensive shape specific tooling (up to $1M each), higher formability (4 times higher) and reduced forming forces (30% lower). Greater formability in DSIF will allow light-weighting and enhanced fuel efficiency, leading to further energy savings. The cost of storing legacy die sets will be eliminated by DSIF, since only part models in the electronic format will be needed for re-fabrication of parts.