A method of incrementally forming workpiece is provided by the present disclosure. In one form, the method includes securing a sacrificial material layer to at least one surface of the workpiece, imparting a force directly to the sacrificial material layer with at least one forming tool, and incrementally forming the workpiece to a desired geometry based on a tool path of the forming tool.

A machining surface of a die are provided with a pair of inclined surfaces facing each other across a gap and a flat surface interposed therebetween. Each inclined surface includes an inner end portion on a side near the flat surface and an outer end portion on a side farther away from the flat surface. The molding method includes a mounting step of mounting the metal sheet on the die to span both inclined surfaces, and a pressing step of forming a reduced-thickness portion by pressing the metal sheet between the punch and the inclined surfaces of the die. The pressing step includes setting a bottom dead center of the punch to maintain a gap formed between the inner end portion and a surface of the metal sheet facing the inner end portion.

A tool for use during double sided incremental forming of a workpiece. The tool includes a sleeve with a hollow interior space. A contact member is positioned within the hollow interior space of the sleeve. The contact member is sized with a working tip positioned outward beyond the sleeve to contact against a workpiece. A mount is positioned on the opposing end of the sleeve and configured to connect to a tool holder. The tool is configured to provide for translational and/or rotational movement of the contact member. The axial and rotational movement provides for the working tip to remain in contact with the workpiece during the forming process.

A method for incrementally forming includes: preparing a tool T disposed on one side of a metal plate W, a fixing jig 1 to hold a periphery of the metal plate W, and a template P1 including a molded edge E that follows at least a part of a contour of a part to be processed F; arranging the template P1 on the other side of the metal plate W; holding the periphery of the metal plate W together with the template P1 by the fixing jig 1 to fix the metal plate W and the template P1; and moving the tool T while pressing the tool T against the metal plate W, to incrementally form the part to be processed F having a three-dimensional shape of the metal plate W.

The method enables to form the part to be processed F in high precision with no use of a molding die and thus, is effective in bringing about reducing cost of equipment and manufacturing.

A method is presented. A tool path having planar parallel alternating paths connected by a plurality of curved transitions is generated. A forming tool is driven along the planar parallel alternating paths and the plurality of curved transitions to shape a material into a workpiece.

A system includes a frame configured to hold a workpiece and first and second tool positioning assemblies configured to be opposed to each other on opposite sides of the workpiece. The first and second tool positioning assemblies each include a toolholder configured to secure a tool to the tool positioning assembly, a first axis assembly, a second axis assembly, and a third axis assembly. The first, second, and third axis assemblies are each configured to articulate the toolholder along a respective axis. Each axis assembly includes first and second guides extending generally parallel to the corresponding axis and disposed on opposing sides of the toolholder with respect to the corresponding axis. Each axis assembly includes first and second carriages articulable along the first and second guides of the axis assembly, respectively, in the direction of the corresponding axis.

The present invention relates to an atypical curved panel forming apparatus and, more specifically, to an atypical curved panel forming apparatus having a novel structure, comprising: a mold block 20 enabling a panel A to be formed to be put on the upper surface thereof; and a pressing means 30 positioned on the upper side of the middle portion of a conveyor device 12 so as to downwardly press the panel A put on a mold, thereby pressing the entire panel A so as to enable the entire panel A to be pressed at constant pressure, enabling the time required for forming the panel A to be minimized, and enabling the atypical curved panel put on the mold block 20 to he effectively formed.

The present invention is directed to a dual sided incremental sheet forming apparatus and method for incrementally forming sheet materials such as sheet metal by utilizing opposed primary and secondary forming tool assemblies and a sheet feeding assembly. The primary forming tool assembly includes a rigid tool and the secondary forming tool assembly includes a compressible and resilient backing layer having either a cylindrical or flat configuration. The sheet feeding assembly positions the sheet material between the two forming tools. The rigid tool applies force to one surface of the sheet material while the resilient backing tool applies counter force to the opposite surface of the work piece as it supports the work piece. This dual sided process localizes the forces on the sheet material so that stresses are advantageously controlled to produce accurately formed asymmetric shapes, without the need for expensive dies. The use of a rigid tool with an opposed resilient backing tool both having linear independent motion also avoids potential wrinkling and tearing of the resulting work piece and enables the formation of numerous, highly detained asymmetric products.

A device for incrementally forming a plurality of workpieces includes a frame configured to receive a workpiece, at least one clamp configured to secure the workpiece to the frame, a first sacrificial material layer configured to be secured to at least one surface of the workpiece, and a first forming tool configured to impart a first force directly to the first sacrificial material layer and incrementally form the workpiece to a desired geometry based on a tool path of the first forming tool. The frame, the at least one clamp, the first sacrificial material layer, and the first forming tool are configured to impart a first force directly to the first sacrificial material layer secured to at least one surface of a first workpiece with the first forming tool and incrementally form the first workpiece to a desired geometry based on a tool path of the first forming tool.

An aerodynamic component of a gas turbine engine is provided and is fittable to a shell having a shell shape. The aerodynamic component includes a body having a component shape initially deviating from the shell shape prior to an assembly operation in which the aerodynamic component is to be fit to the shell. Deviation of the component shape from the shell shape aids in an establishment of a final desired shape of the aerodynamic component following the assembly operation.