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Updated: May 14, 2026
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Simulation of a Scaled Assembly Process with Collaboration of a Robotic Arm and Monitoring through a Vision System for Quality Control
Published on: August 29, 2025
Influence of Tool-Axis Orientation on Dimensional Accuracy in Robot-Based Single Point Incremental Forming
Alexandru Bârsan1, Iosif-Adrian Maroșan1, Sever-Gabriel Racz1
1Department of Industrial Machines and Equipment, Engineering Faculty, Lucian Blaga University of Sibiu, Victoriei 10, 550024 Sibiu, Romania.
Materials (Basel, Switzerland)
|May 13, 2026
Summary
Robot-based single point incremental forming (RB-SPIF) accuracy improves with smaller step sizes and a wall-normal tool-axis. This adaptive orientation enhances part precision by optimizing tool-sheet contact.
Area of Science:
- Manufacturing Engineering
- Materials Science
- Robotics
Background:
- Single Point Incremental Forming (SPIF) offers a die-less method for complex sheet metal parts.
- Achieving high dimensional accuracy in SPIF is challenging due to springback and deformation.
- Robot-based SPIF (RB-SPIF) presents opportunities for flexible manufacturing.
Purpose of the Study:
- To investigate the impact of tool-axis orientation on dimensional accuracy in RB-SPIF.
- To evaluate the influence of toolpath strategies and step sizes.
- To identify methods for enhancing geometric precision in incremental sheet forming.
Main Methods:
- Experimental analysis of eight cases varying toolpath (contour/spiral), step size (0.5/1 mm), and tool-axis (fixed/wall-normal).
- Utilized optical 3D scanning and cross-sectional profile analysis for dimensional accuracy assessment.
- Focused on robot-based single point incremental sheet forming (RB-SPIF) process.
Main Results:
- Smaller vertical step sizes (0.5 mm) resulted in profiles closer to the nominal geometry.
- Spiral toolpaths showed a slight, though not statistically significant, improvement over contour paths.
- A wall-normal tool-axis configuration significantly enhanced dimensional accuracy by optimizing tool-sheet contact.
Conclusions:
- Vertical step size is a critical factor for dimensional accuracy in RB-SPIF.
- Adaptive tool-axis orientation, specifically wall-normal, is a promising strategy for improving precision.
- RB-SPIF can achieve higher accuracy through optimized process parameters and toolpath control.
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