Comparison of Design Approaches to Generate Tools for a Forming Process with a Six Degree of Freedom Press

Abstract

Tool design for multi-axis forming presses is a particular challenge. In this forming process, the material flow can be controlled with the help of the tool motion path. The multi-axis forming tools used for this purpose differ from linear pressing tools, which are narrowly defined by the workpiece geometry. These multi-axial tools also differ from incremental sheet forming tools, which have a universal tool and form the workpiece geometry by a complex tool motion path. The design of tools for multi-axial forming presses has to take both, the workpiece geometry and the tool motion path, into account. The investigated tool designs base on ‘point-‘, ‘line-‘ and ‘area-wise’ approaches to generate the shape of the mold from the workpiece geometry. In ‘point-wise’ approach, the surface of the workpiece is tessellated and transformed to the tool surface by using base layers depending on the tool motion path. In ‘line-wise’ approach, intersecting lines between workpiece and datum planes perpendicular to toolpath are transformed to a tool base geometry generating a mold’s surface. In ‘area-wise’ approach, the geometry is generated by moving the workpiece along an inverted tool path and shaping the surface of a generic tool with Boolean operations. By benchmarking all approaches to a known ideal tool geometry, the effort and the quality of the resulting tool surface can be evaluated. For unknown tool geometries the approaches were applied in two steps. In the first step a tool geometry can be generated with a nominal workpiece and in a second step a virtual workpiece with the tool. The virtual workpieces of all approach combinations were compared to the nominal workpiece. Finally, the tool design approaches, the results of the deviation between the virtual and the nominal workpiece geometry as well as the evaluation method are discussed.

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Titel	Comparison of Design Approaches to Generate Tools for a Forming Process with a Six Degree of Freedom Press
Medien	AIP Conference Proceedings
Verlag	AIP Publishing LLC
Heft	1
Band	2113
ISBN	---
Verfasser/Herausgeber	Birk Wonnenberg, Prof. Dr.-Ing. Anke Müller, Klaus Dröder
Seiten	---
Veröffentlichungsdatum	02.07.2019
Projekttitel	---
Zitation	Wonnenberg, Birk; Müller, Anke; Dröder, Klaus (2019): Comparison of Design Approaches to Generate Tools for a Forming Process with a Six Degree of Freedom Press. AIP Conference Proceedings 2113 (1).