Research on incremental sheet forming started decades ago but has not yet found its momentum. To become a mainstream technology, two key enablers are required: geometrical accuracy and usability. Double sided incremental forming (DSIF) is a promising improvement but comes with additional challenges, such as tool path definition. National Research Council Canada (NRC) is tackling these specific problems for robotic DSIF.
This conference paper will present a novel strategy to determine tool positioning without using squeezing factor, sine law, or other conventional techniques. First, the master toolpath is calculated with CAM software. Then, a numerical coupling between the master and the slave is imposed to precisely simulate their positions while ensuring continuous contact and a variable support force. Upstream deformations are thus minimized throughout the complete forming of the part. This strategy was applied to different geometries, and the numerical results show only slight deviations from CAD.