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

SBIR 第一阶段：用于快速无模金属板材制造的双面增量成形系统

• 批准号: 1248823
• 负责人: Michael Beltran
• 金额: $ 15万
• 依托单位: Scimplicity LLC
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2013
• 资助国家: 美国
• 起止时间: 2013-01-01 至 2013-06-30
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1248823&HistoricalAwards=false
• 关键词: SBIR; Phase; Double; Sided; Incremental

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.

这个小企业创新研究（SBIR）第一阶段项目将解决与创新无模金属板材成形工艺双面增量成形（DSIF）商业化相关的关键技术挑战。DSIF局部变形周边夹紧的金属板件使用一个小的半球形结束的工具在板的两侧，每个移动沿着一个预先确定的tool路径。当前的tool路径生成方法不考虑在成形过程中的板变形的力学，导致不可接受的高成形时间和不令人满意的几何精度。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期间金属板材的变形力学，以实现500 μ m或更小的零件精度，同时保持用户定义的吞吐量。此外，还将设计一个新的DSIF成形中心，可以使用高强度合金成形大型部件，这些部件需要高机器刚度和成形力。这项工作将提供一个重要的科学和技术基础，走向商业化的DSIF快速原型和小批量生产的钣金parts.The更广泛的/商业潜力，这个项目是显着降低成本的快速原型和小批量制造的优质钣金零件，消除了昂贵的模具组的需要。将变形力学纳入DSIF刀具路径规划将在DSIF中的刀具路径与成形产品的最终几何形状和应力之间建立强有力的联系。因此，迭代的实验过程中，最佳的刀具路径生成将被取代的结构化，科学和更强大的刀具路径生成方法。与传统成形相比，DSIF的优点包括不需要昂贵的特定形状工具（每个高达100万美元），更高的成形性（高4倍）和降低的成形力（低30%）。DSIF更大的可成形性将允许轻量化和提高燃油效率，从而进一步节省能源。DSIF将消除存储传统模具组的成本，因为只有电子格式的零件模型才能用于零件的重新制造。