A multi-stage incremental sheet forming system includes a forming tool, and at least one control unit in communication with the forming tool. The at least one control unit is configured to determine a convex hull of a target structure to be formed by the forming tool. The at least one control unit is further configured to operate the forming tool according to a first tool path in relation to an initial structure to form an intermediate structure having a shape based on the convex hull of the target structure. The at least one control unit is further configured to operate the forming tool according to a second tool path in relation to the intermediate structure to form one or more inward features into the intermediate structure to form the target structure.

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 be effectively formed.

A system and method for forming a structure with steep walls (walls having an angle greater than 60° with respect to a level plane) through one or more incremental sheet forming operations is provided. The method includes a workpiece with an inner region and an outer region that are separated by a boundary region. The boundary region includes a plurality of openings and a plurality of connecting elements. The openings are cut into the workpiece using a boundary region cutting tool. A forming tool is configured to operate on the inner region after the boundary region cutting operation has been completed. At least one control unit is in communication with the forming tool. The at least one control unit operates the forming tool to form the structure from the inner region.

A method of forming a component by applying a forming load to a blank of material against a mandrel, wherein the mandrel defines the shape of the component to be formed and applying a forming load as a combination of a localised force and localised friction heating.

A slope-matched stylus (SMS) tool for Incremental Sheet Forming (ISF) of a sheet includes a shaft connected to a stylus body and to a multi-axis drive mechanism. The stylus body has a conical or generally frustoconical form which includes a tool surface defining one or more corresponding tool wall angles. The tool wall angle range matches one or more part wall angles of a part formed via the ISF process, such that a flat line of contact exists between the stylus body and sheet. The tool and part wall angles are complementary. A system includes the tool and drive mechanism. A method includes securing the sheet to a fixture, connecting the tool to the drive mechanism, and progressively pressing a tool surface of the stylus body into or against the sheet using the drive mechanism, controlling the latter to ensure a flat line of contact is provided between the stylus body and sheet.

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.

An electrically assisted forming process and device for a high-strength metal alloy thin-walled pipe includes a die sleeve, wiring terminals, a pulse power supply, a die seat, sealing baffle plates, a drawing die, and a cooling water circulation chamber. A process for forming a high-strength metal alloy thin-walled pipe includes first, graphite or fusible metal, i.e., an aluminum rod, is introduced into a high-strength metal alloy pipe to be drawn to fill the whole pipe; and then, pulse current is introduced into a plastic deformation area of the thin-walled pipe. A cooling device can be provided to achieve a good cooling effect. The thin-walled pipe with corresponding length is cut according to a production requirement after processing is completed, and annealing treatment is performed in a vacuum heat treatment furnace.

A method of radial incremental forming a component having a component inner mold line (IML) includes providing a mandrel having geometry configured to mate with the IML. The method also includes inserting the mandrel into a tubular workpiece composed of a formable material, to thereby sleeve the workpiece over the mandrel. The method additionally includes mounting the workpiece sleeved over the mandrel onto a drive mechanism configured to rotate the mandrel and having a forming tool configured to shift relative to the workpiece. The method further includes regulating, according to provided toolpath instructions, the drive mechanism to rotate the workpiece sleeved over the mandrel in concert with shifting the forming tool relative to the workpiece to incrementally deform the workpiece therewith over the mandrel and thereby form the component. A tool system having an electronic controller may employ the subject method to radially incrementally form a component.

Flanges formed on sheet metal parts to increase the part stiffness or create mating surface for further assembly are created in an incremental sheet forming process using forming tool and supporting tool that move along a specified tool path so as to gradually deform a peripherally-clamped sheet metal work piece into the desired geometry. With two universal tools moving along the designed toolpath on the both sides of the part, the process is very flexible. Process time is can also be reduced by utilizing an accumulative double-sided incremental hole-flanging strategy, in which the flange is formed in only one step.

An apparatus of holding a blank for incremental forming, includes a blank holder to which a blank is configured to be coupled; a motor configured to provide driving power; an interlocking means engaged to the motor and configured to rectilinearly move the blank holder in a direction perpendicular to a forming surface of the blank in conjunction with an operation of the motor; and a controller configured to control the operation of the motor so that the blank rectilinearly moves in accordance with a position of a forming robot configured for forming the blank.