Abstract
Incremental sheet forming (ISF) is an emerging forming technology that promises high flexibility and formability. These properties make it suited for small-scale and customised production. However, the poor geometric accuracy of ISF limits the wide application of this flexible forming technology. This paper presents a two-directional toolpath correction approach to enhance ISF forming accuracy using a model predictive control (MPC) algorithm. A toolpath optimisation method for vertical toolpath correction has been validated in our previous work (Lu et al., Int J Adv Manuf Technol 72:1–14, 2015), and it helps to reduce errors in the base of the test shapes to a suitable level while its major limitation is that horizontal geometric errors are relatively large. This paper extends our previous work (Lu et al., Int J Adv Manuf Technol 72:1–14, 2015) by augmenting the vertical control module with a new control module for horizontal toolpath correction. The proposed control algorithm was experimentally validated in single-point incremental sheet forming (SPIF) using two forming case studies. In the first case study (a truncated pyramid), two control approaches with different assumptions for the horizontal springback distribution along the horizontal cross-sectional profile were tested and compared. Then, the developed MPC control algorithm was applied to form a more complex asymmetric shape. The results show that the developed strategy can reduce the forming errors in the wall and base of the formed shape compared to the existing works. The ISF process with MPC control leads to significant accuracy improvement in comparison with the typical ISF process that is without toolpath control.
Similar content being viewed by others
References
Lu H, Kearney M, Li Y, Liu S, Daniel WT, Meehan P (2015) Model predictive control of incremental sheet forming for geometric accuracy improvement. Int J Adv Manuf Technol 82:1781–1794
Micari F, Ambrogio G, Filice L (2007) Shape and dimensional accuracy in single point incremental forming: state of the art and future trends. J Mater Process Technol 191:390–395
Attanasio A, Ceretti E, Giardini C (2006) Optimization of tool path in two points incremental forming. J Mater Process Technol 177:409–412
Ambrogio G, Napoli L, Filice L (2009) A novel approach based on multiple back-drawing incremental forming to reduce geometry deviation. Int J Mater Form 2:9–12
Araghi BT, Manco GL, Bambach M, Hirt G (2009) Investigation into a new hybrid forming process: incremental sheet forming combined with stretch forming. Cirp Ann-Manuf Techn 58:225–228
Behera AK, Lauwers B, Duflou JR (2014) Tool path generation for single point incremental forming using intelligent sequencing and multi-step mesh morphing techniques. Int J Mater Form 8:517–532
Bambach M, Taleb Araghi B, Hirt G (2009) Strategies to improve the geometric accuracy in asymmetric single point incremental forming. Prod Eng 3:145–156
Ambrogio G, Costantino I, De Napoli L, Filice L, Fratini L, Muzzupappa M (2004) Influence of some relevant process parameters on the dimensional accuracy in incremental forming: a numerical and experimental investigation. J Mater Process Technol 153–154:501–507
Hirt G, Ames J, Bambach M, Kopp R, Kopp R (2004) Forming strategies and process modelling for CNC incremental sheet forming. CIRP Ann Manuf Technol 53:203–206
Behera AK, Verbert J, Lauwers B, Duflou JR (2013) Tool path compensation strategies for single point incremental sheet forming using multivariate adaptive regression splines. Comput Aided Des 45:575–590
Fiorentino A, Feriti GC, Giardini C, Ceretti E (2015) Part precision improvement in incremental sheet forming of not axisymmetric parts using an artificial cognitive system. J Manuf Syst 35:215–222
Allwood JM, Music O, Raithathna A, Duncan SR (2009) Closed-loop feedback control of product properties in flexible metal forming processes with mobile tools. CIRP Ann Manuf Technol 58:287–290
Wang H, Duncan S, (2011) Optimization of tool trajectory for incremental sheet forming using closed loop control, in: Automation Science and Engineering (CASE), 2011 I.E. Conference on, pp. 779–784
Wang H, Duncan S (2011) Constrained model predictive control of an incremental sheet forming process, in: Control Applications (CCA), IEEE International Conference on, 2011, pp. 1288–1293
Camacho EF, Alba CB, (2013) Model predictive control, Springer Science & Business Media
Echrif SBM, Hrairi M (2011) Research and progress in incremental sheet forming processes. Mater Manuf Process 26:1404–1414
Li Y, Liu Z, Daniel WJT, Meehan PA (2014) Simulation and experimental observations of effect of different contact interfaces on the incremental sheet forming process. Mater Manuf Process 29:121–128
Yilamu K, Hino R, Hamasaki H, Yoshida F (2010) Air bending and springback of stainless steel clad aluminum sheet. J Mater Process Technol 210:272–278
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Lu, H., Kearney, M., Liu, S. et al. Two-directional toolpath correction in single-point incremental forming using model predictive control. Int J Adv Manuf Technol 91, 91–106 (2017). https://doi.org/10.1007/s00170-016-9672-3
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-016-9672-3