Investigation of Advanced Robotized Polymer Sheet Incremental Forming Process

Area of Science:

• Materials Science and Engineering
• Manufacturing Processes

Background:

• Traditional polymer forming methods can be costly for small batches.
• Single Point Incremental Forming (SPIF) offers potential for low-volume production but faces challenges with polymer materials.

Purpose of the Study:

• To investigate an inexpensive method for producing small-batch polymer sheet components using robotized SPIF without backing plate support.
• To develop and evaluate an innovative thermal and ultrasound-assisted deformation technique for polymers.

Main Methods:

• Development of a novel tool with a laser-heated sphere in a magnetic holder, utilizing ultrasound to reduce friction.
• Application of Finite Element Method (FEM) for virtual evaluation of SPIF deformation parameters.
• Experimental analysis of polyvinyl chloride (PVC) sheet deformation using the proposed method.

Main Results:

• The thermal and ultrasound-assisted SPIF method successfully increased local polymer plasticity with reduced deforming force.
• Elimination of the need for a backing plate was achieved, maintaining overall polymer stiffness.
• Improved surface quality of formed polymer components was observed due to the rolling action of the free-rotating ball tool.

Conclusions:

• The proposed method enables cost-effective, small-batch production of polymer components via SPIF.
• The combined thermal and ultrasound assistance is effective in overcoming challenges associated with polymer incremental forming.
• This technique offers a viable alternative for manufacturing customized polymer parts without traditional support structures.