New approaches in incremental sheet forming with a robot system for an industrial work-piece

This paper introduces new results of the single point incremental forming process of an industrial sheet metal component. Incremental sheet forming (ISF) is an innovative and compared to conventional forming technologies which does require forming tools like a specific die and punch, a costeffective forming method for prototyping and limited-lot production. Moving a hammer tool on a generated path above the sheet metal one can manufacture a three dimensional complex sheet metal product. Contrary to deep drawing process and due to the low forming forces since using a high frequent hammer tool a common industrial robot can be applied. A robot with handling payloads of 400 kg was sufficient. Thus this ISF-process enables production of sheet metal parts and preliminary models at low costs. This article describes the development of the incremental hammering process and the advantages compared to existing forming and incremental forming methods and strategies. Furthermore influences and interacting parameters of ISF using a robot are shown. Problems of ISF with complex industrial parts will be discussed, e.g. when slight and big and long geometry variations are positioned next to each other, where distortion and thus inacceptability of customers may occur. Therefore approaches of solutions need to be done in future will be shown in this paper to prove the industrial functionality and application of the hammer forming technology. To be able to give a statement about the accuracy of the formed parts a three-dimensional laser sensor has been installed measuring the workpieces.