Toolpath Planning and Generation for Multi-Stage Incremental Forming Based on Stretching Angle.

Area of Science:

• Manufacturing Engineering
• Materials Science
• Mechanical Engineering

Background:

• Multi-stage incremental forming of straight wall parts faces challenges like sheet fracture, uneven thickness, and feature sinking.
• Existing methods struggle to control material flow and maintain dimensional accuracy.

Purpose of the Study:

• To propose a new forming toolpath planning and generation method for multi-stage incremental forming based on the stretching angle.
• To address limitations in current forming techniques for straight wall parts.

Main Methods:

• Developed a forming toolpath strategy using parallel planes defined by a stretching angle, gradually reducing distances and angles.
• Created a software system for toolpath generation using C++, VC++, and OpenGL.
• Validated the method through numerical simulations and forming experiments on 1060 aluminum sheets, comparing with single-stage and traditional multi-stage forming.

Main Results:

• The proposed method significantly improves thickness distribution uniformity.
• It enhances profile dimension accuracy and reduces sinking and bulging defects.
• Forming with a 15° stretching angle yielded superior dimensional accuracy, less bottom subsidence, and greater thickness compared to a 5° angle.

Conclusions:

• The stretching angle-based toolpath planning method is feasible and effective for multi-stage incremental forming.
• This approach overcomes common issues in forming straight wall parts, leading to higher quality components.
• Optimizing the stretching angle is crucial for achieving desired part accuracy and material properties.