EP1462190A1 - Method and apparatus for incremental forming - Google Patents

Method and apparatus for incremental forming Download PDF

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Publication number
EP1462190A1
EP1462190A1 EP03255335A EP03255335A EP1462190A1 EP 1462190 A1 EP1462190 A1 EP 1462190A1 EP 03255335 A EP03255335 A EP 03255335A EP 03255335 A EP03255335 A EP 03255335A EP 1462190 A1 EP1462190 A1 EP 1462190A1
Authority
EP
European Patent Office
Prior art keywords
workpiece
incremental forming
form portion
forming
incremental
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP03255335A
Other languages
German (de)
French (fr)
Other versions
EP1462190B1 (en
Inventor
Norihisa c/o Hitachi Ltd. IP Group Okada
Gen Ro
Yohji Suzuki
Masatoshi Nara
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Hitachi Ltd
Amino Corp
Original Assignee
Hitachi Ltd
Amino Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Hitachi Ltd, Amino Corp filed Critical Hitachi Ltd
Publication of EP1462190A1 publication Critical patent/EP1462190A1/en
Application granted granted Critical
Publication of EP1462190B1 publication Critical patent/EP1462190B1/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/14—Spinning
    • B21D22/18—Spinning using tools guided to produce the required profile
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/14—Spinning
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D31/00—Other methods for working sheet metal, metal tubes, metal profiles
    • B21D31/005—Incremental shaping or bending, e.g. stepwise moving a shaping tool along the surface of the workpiece

Definitions

  • the present invention relates to an incremental forming method and an incremental forming apparatus.
  • Patent document 1 Japanese Patent Laid-Open Publication No. 2002-1444 (European Patent Application Publication No. 1147832 A2) discloses an incremental forming method according to which a rod shaped tool is applied to the surface of a metal plate material and incremental forming is performed by shaping the plate member with the tool along a contour line corresponding to the shape of the product to be formed.
  • FIG. 1 is a perspective view showing the product manufactured through incremental forming that applies the present invention.
  • the product comprises a primary formportion 10 having a two-dimensional curved cross-sectional shape, and a secondary form portion 20 having a three-dimensional shape and protruding from the center of the primary form portion 10.
  • FIGS. 5 through 9 illustrate the conventional process for manufacturing the product 1 through conventional incremental forming.
  • a forming jig 100 disposed on a table 50 includes a first mold member 110 corresponding to the primary form portion 10 of the product and a second mold member 120 corresponding to the secondary form portion 20 of the product.
  • a metal plate 140 being the workpiece (base material) is a flat plate-shaped member, having its periphery supported by a workpiece holder 130 and a workpiece clamp 150.
  • the workpiece holder 130 can be lowered from the peak area of the second mold member.
  • An incremental forming tool 160 has an axis that is disposed along the perpendicular direction Z, and is capable of moving both in the horizontal direction X, Y and perpendicular direction Z.
  • FIG. 6 is a schematic view of the conventional incremental forming
  • FIG. 7 shows the forming path.
  • the incremental forming tool 160 moves along the X-Y axis parallel to the upper surface of a plate-shaped workpiece 140, while moving in the Z axis direction corresponding to a pitch P at a time.
  • plural incremental forming tools 160 illustrated in each of the drawings in FIG. 8 actually there is only one incremental forming tool.
  • Three tools 160 are illustrated in each drawing to show that the tool is moved along a contour line.
  • FIG. 9(a) shows a state in which the incremental forming process is completed and a primary formportion 10 and a secondary form portion 20 are created on the workpiece 140.
  • the workpiece 140 is subj ected to an appropriate trimming process C 1 for trimming the peripheral area of the workpiece to correspond to the product, thereby forming the product 1.
  • the workpiece 140 is left with an end material having a space 142 from which the product is cut out by the trimming, which causes deterioration of the yield factor of the material.
  • the present invention aims at providing a method and apparatus for incremental forming that overcomes the above-mentioned problems of the prior art.
  • the three-dimensional incremental forming method involves preparing a workpiece having a curved plane corresponding to the primary form portion, and forming a three-dimensional secondary form portion to a part of this workpiece via incremental forming.
  • the incremental forming apparatus comprises a table mounting a workpiece holder and a workpiece clamp for holding the periphery of a workpiece, and an incremental forming tool disposed to have its axial direction perpendicular to the table, wherein the workpiece holder and the workpiece clamp have curved surfaces that correspond to the curved plane of the workpiece.
  • FIGS. 2 through 4 are explanatory views illustrating the method for creating a product by the incremental forming according to the present invention.
  • a forming jig 200 positioned on a table 50 comprises only a mold member 220 corresponding to a secondary form portion of the product.
  • a metal plate 240 being the workpiece (material) is formed in advance into a curved plate having a two-dimensional curved surface that corresponds to a primary formportion of the product.
  • a workpiece holder 230 comprises a holder surface 232 that corresponds to the curved surface of the workpiece 240.
  • a workpiece clamp 250 has a clamp surface 252 that corresponds to the curved surface of the workpiece 240.
  • an incremental forming tool 260 and the table are relatively moved along the planar shape of the secondary form portion on an X-Y plane, and when the incremental forming tool 260 is relatively moved in the Y axis direction, the tool 260 is controlled so that it moves along the primary form portion, that is, along the curved surface of the workpiece 240.
  • the incremental forming tool 260 is advanced by a predetermined pitch P 2 to create the secondary form portion, in a manner similar to the conventional incremental forming.

Abstract

In forming a secondary form portion having a three-dimensional shape to apart of a primary form portion having a two-dimensional curved plane, a work 240 having a curved plane corresponding to the shape of the primary formportion is prepared, and only the secondary form portion is created by incremental forming.

Description

    FIELD OF THE INVENTION
  • The present invention relates to an incremental forming method and an incremental forming apparatus.
    • DESCRIPTION OF THE RELATED ART
  • Patent document 1, Japanese Patent Laid-Open Publication No. 2002-1444 (European Patent Application Publication No. 1147832 A2) discloses an incremental forming method according to which a rod shaped tool is applied to the surface of a metal plate material and incremental forming is performed by shaping the plate member with the tool along a contour line corresponding to the shape of the product to be formed.
  • FIG. 1 is a perspective view showing the product manufactured through incremental forming that applies the present invention.
  • The product, the whole structure of which being designated by reference number 1, comprises a primary formportion 10 having a two-dimensional curved cross-sectional shape, and a secondary form portion 20 having a three-dimensional shape and protruding from the center of the primary form portion 10.
  • FIGS. 5 through 9 illustrate the conventional process for manufacturing the product 1 through conventional incremental forming.
  • A forming jig 100 disposed on a table 50 includes a first mold member 110 corresponding to the primary form portion 10 of the product and a second mold member 120 corresponding to the secondary form portion 20 of the product.
  • A metal plate 140 being the workpiece (base material) is a flat plate-shaped member, having its periphery supported by a workpiece holder 130 and a workpiece clamp 150. The workpiece holder 130 can be lowered from the peak area of the second mold member. An incremental forming tool 160 has an axis that is disposed along the perpendicular direction Z, and is capable of moving both in the horizontal direction X, Y and perpendicular direction Z.
  • FIG. 6 is a schematic view of the conventional incremental forming, and FIG. 7 shows the forming path.
  • As illustrated in FIGS. 6 and 7, incremental forming is performed throughout the whole workpiece via a path P1 for forming the first form portion and a path P2 for forming the second form portion, thereby shaping the workpiece to create a product.
  • As shown in FIG. 8, during incremental forming, the incremental forming tool 160 moves along the X-Y axis parallel to the upper surface of a plate-shaped workpiece 140, while moving in the Z axis direction corresponding to a pitch P at a time. Though there are plural incremental forming tools 160 illustrated in each of the drawings in FIG. 8, actually there is only one incremental forming tool. Three tools 160 are illustrated in each drawing to show that the tool is moved along a contour line.
  • When the pitch P for moving the tool in the Z direction is constant, the forming of the workpiece is progressed along a contour line. If the radius of curvature of the curved plane of the first form portion is large, the distance between the adjacent paths is widened, deteriorating formability.
  • However, if the pitch is narrowed to improve formability and to overcome the above problem, another drawback is caused in that the total length of the form path is increased and the total work time lengthened.
  • FIG. 9(a) shows a state in which the incremental forming process is completed and a primary formportion 10 and a secondary form portion 20 are created on the workpiece 140.
  • Thereafter, the workpiece 140 is subj ected to an appropriate trimming process C1 for trimming the peripheral area of the workpiece to correspond to the product, thereby forming the product 1.
  • After the trimming process, the workpiece 140 is left with an end material having a space 142 from which the product is cut out by the trimming, which causes deterioration of the yield factor of the material.
    • SUMMARY OF THE INVENTION
  • Therefore, the present invention aims at providing a method and apparatus for incremental forming that overcomes the above-mentioned problems of the prior art.
  • In order to achieve the above object, the three-dimensional incremental forming method according to the present invention involves preparing a workpiece having a curved plane corresponding to the primary form portion, and forming a three-dimensional secondary form portion to a part of this workpiece via incremental forming.
  • The incremental forming apparatus according to the present invention comprises a table mounting a workpiece holder and a workpiece clamp for holding the periphery of a workpiece, and an incremental forming tool disposed to have its axial direction perpendicular to the table, wherein the workpiece holder and the workpiece clamp have curved surfaces that correspond to the curved plane of the workpiece.
    • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1 is a perspective view of the product formed according to the present invention;
  • FIG. 2 is a perspective view of the device used in the present invention;
  • FIG. 3 is an explanatory view illustrating the preferred embodiment of the present invention;
  • FIG. 4 is an explanatory view illustrating the preferred embodiment of the present invention;
  • FIG. 5 is a perspective view showing the device used according to the prior art;
  • FIG. 6 is an explanatory view showing the incremental forming according to the prior art;
  • FIG. 7 is an explanatory view showing the incremental forming according to the prior art;
  • FIG. 8 is an explanatory view showing the incremental forming according to the prior art; and
  • FIG. 9 is an explanatory view showing the incremental forming according to the prior art.
    • DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
  • FIGS. 2 through 4 are explanatory views illustrating the method for creating a product by the incremental forming according to the present invention.
  • According to the present invention, a forming jig 200 positioned on a table 50 comprises only a mold member 220 corresponding to a secondary form portion of the product.
  • A metal plate 240 being the workpiece (material) is formed in advance into a curved plate having a two-dimensional curved surface that corresponds to a primary formportion of the product.
  • A workpiece holder 230 comprises a holder surface 232 that corresponds to the curved surface of the workpiece 240. Similarly, a workpiece clamp 250 has a clamp surface 252 that corresponds to the curved surface of the workpiece 240.
  • During the forming process, an incremental forming tool 260 and the table are relatively moved along the planar shape of the secondary form portion on an X-Y plane, and when the incremental forming tool 260 is relatively moved in the Y axis direction, the tool 260 is controlled so that it moves along the primary form portion, that is, along the curved surface of the workpiece 240.
  • Along with the advancement of the forming process, the incremental forming tool 260 is advanced by a predetermined pitch P2 to create the secondary form portion, in a manner similar to the conventional incremental forming.
  • As shown in FIG. 4, since according to the present invention a two-dimensional curve is provided in advance to the workpiece 240 and only the secondary form portion having a three-dimensional structure is processed by incremental forming, the form path can be shortened greatly and the work time cut down.

Claims (4)

  1. An incremental forming method for forming a product comprising a primary form portion having a cross-section with a two-dimensional curved plane and a secondary form portion having a three-dimensional shape formed to a part of the primary form portion, the incremental forming method comprising:
    preparing a workpiece having a curved plane corresponding to the primary form portion; and
    forming the secondary form portion having the three-dimensional shape to a part of the workpiece via incremental forming.
  2. The incremental forming method according to claim 1, wherein
       during the incremental forming process for forming the secondary form portion, an incremental forming tool is moved along a path parallel to the curved plane of the primary form portion.
  3. An incremental forming apparatus comprising:
    a table mounting a workpiece holder and a workpiece clamp for holding a periphery of a workpiece; and
    an incremental forming tool having an axis disposed substantially perpendicular to the table;
       wherein the workpiece holder and the workpiece clamp have curved surfaces corresponding to a curved surface of the workpiece.
  4. The incremental forming apparatus according to claim 3, further comprising a forming jig having a shape corresponding only to a secondary form portion.
EP03255335A 2003-03-28 2003-08-28 Method and apparatus for incremental forming Expired - Lifetime EP1462190B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2003089942 2003-03-28
JP2003089942A JP4322033B2 (en) 2003-03-28 2003-03-28 Sequential forming method and apparatus

Publications (2)

Publication Number Publication Date
EP1462190A1 true EP1462190A1 (en) 2004-09-29
EP1462190B1 EP1462190B1 (en) 2006-03-29

Family

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Family Applications (1)

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EP03255335A Expired - Lifetime EP1462190B1 (en) 2003-03-28 2003-08-28 Method and apparatus for incremental forming

Country Status (9)

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US (1) US20040187548A1 (en)
EP (1) EP1462190B1 (en)
JP (1) JP4322033B2 (en)
KR (1) KR100545293B1 (en)
CN (1) CN1282509C (en)
AT (1) ATE321617T1 (en)
AU (1) AU2003244039A1 (en)
DE (1) DE60304298T2 (en)
TW (1) TWI288671B (en)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2006110962A2 (en) * 2005-04-22 2006-10-26 K.U.Leuven Research And Development Asymmetric incremental sheet forming system
US20140042683A1 (en) * 2012-08-10 2014-02-13 Ford Global Technologies, Llc Fixture Assembly for Forming Prototype Parts on an Incremental Forming Machine
EP2806711A1 (en) * 2013-05-06 2014-11-26 The Boeing Company Incremental Sheet Forming for Fabrication of Cold Sprayed Smart Susceptor
US10144048B2 (en) 2014-11-19 2018-12-04 Ford Global Technologies, Llc High stiffness and high access forming tool for incremental sheet forming

Families Citing this family (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8322176B2 (en) * 2009-02-11 2012-12-04 Ford Global Technologies, Llc System and method for incrementally forming a workpiece
US8733143B2 (en) 2010-07-15 2014-05-27 Ford Global Technologies, Llc Method of incremental forming with successive wrap surfaces
US8783078B2 (en) 2010-07-27 2014-07-22 Ford Global Technologies, Llc Method to improve geometrical accuracy of an incrementally formed workpiece
US8302442B2 (en) 2010-07-29 2012-11-06 Ford Global Technologies, Llc Method of incrementally forming a workpiece
JP6072433B2 (en) * 2012-05-23 2017-02-01 株式会社アミノ Sequential molding method and apparatus
JP2013252557A (en) * 2012-06-08 2013-12-19 Amino:Kk Sequential forming method
DE102014014202A1 (en) * 2014-09-22 2016-03-24 Technische Universität Dortmund Method and device for the combined production of components by means of incremental sheet metal forming and additive processes in one setting
US10478897B2 (en) * 2017-01-04 2019-11-19 GM Global Technology Operations LLC Sheet metal system and manufacturing process joining incremental forming and direct metal deposition
US10976716B2 (en) * 2018-03-16 2021-04-13 The Boeing Company Generating a plurality of curved transitions connecting planar parallel alternating paths for forming a workpiece
CN112517746B (en) * 2019-09-17 2022-07-12 东南大学 Adaptive control incremental forming method

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JPH11207413A (en) * 1998-01-21 1999-08-03 Toyota Central Res & Dev Lab Inc Incremental forming method
US6006576A (en) * 1997-09-18 1999-12-28 Cosma International Inc. Super stretch draw die and method
EP0970764A1 (en) * 1998-01-29 2000-01-12 Amino Corporation Apparatus for dieless forming plate materials
JP2002102945A (en) * 2000-09-25 2002-04-09 Honda Motor Co Ltd Incremental stretch forming tool

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DE10303458A1 (en) * 2003-01-29 2004-08-19 Amino Corp., Fujinomiya Shaping method for thin metal sheet, involves finishing rough forming body to product shape using tool that moves three-dimensionally with mold punch as mold surface sandwiching sheet thickness while mold punch is kept under pushed state
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US6006576A (en) * 1997-09-18 1999-12-28 Cosma International Inc. Super stretch draw die and method
JPH11207413A (en) * 1998-01-21 1999-08-03 Toyota Central Res & Dev Lab Inc Incremental forming method
EP0970764A1 (en) * 1998-01-29 2000-01-12 Amino Corporation Apparatus for dieless forming plate materials
JP2002102945A (en) * 2000-09-25 2002-04-09 Honda Motor Co Ltd Incremental stretch forming tool

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Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2006110962A2 (en) * 2005-04-22 2006-10-26 K.U.Leuven Research And Development Asymmetric incremental sheet forming system
WO2006110962A3 (en) * 2005-04-22 2007-01-11 Leuven K U Res & Dev Asymmetric incremental sheet forming system
US7984635B2 (en) 2005-04-22 2011-07-26 K.U. Leuven Research & Development Asymmetric incremental sheet forming system
US20140042683A1 (en) * 2012-08-10 2014-02-13 Ford Global Technologies, Llc Fixture Assembly for Forming Prototype Parts on an Incremental Forming Machine
US9038999B2 (en) * 2012-08-10 2015-05-26 Ford Global Technologies, Llc Fixture assembly for forming prototype parts on an incremental forming machine
EP2806711A1 (en) * 2013-05-06 2014-11-26 The Boeing Company Incremental Sheet Forming for Fabrication of Cold Sprayed Smart Susceptor
US9635714B2 (en) 2013-05-06 2017-04-25 The Boeing Company Incremental sheet forming for fabrication of cold sprayed smart susceptor
US10144048B2 (en) 2014-11-19 2018-12-04 Ford Global Technologies, Llc High stiffness and high access forming tool for incremental sheet forming

Also Published As

Publication number Publication date
KR100545293B1 (en) 2006-01-24
TW200418591A (en) 2004-10-01
KR20040086090A (en) 2004-10-08
ATE321617T1 (en) 2006-04-15
JP4322033B2 (en) 2009-08-26
DE60304298T2 (en) 2006-11-16
DE60304298D1 (en) 2006-05-18
EP1462190B1 (en) 2006-03-29
US20040187548A1 (en) 2004-09-30
CN1533853A (en) 2004-10-06
AU2003244039A1 (en) 2004-10-14
JP2004291065A (en) 2004-10-21
CN1282509C (en) 2006-11-01
TWI288671B (en) 2007-10-21

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