The paper has shown the experiments performed at the Polytechnic University of Marche in Ancona to assess the opportunity of using a robotised cell for the incremental forming of metal sheet parts. Since conventional industrial robots do not have the stiffness nor the accuracy that is required for the operation, a hybrid robot based on parallel actuation for shoulder motions has been used: the complex kinematics of the machine needed the development of a special purpose simulation environment to design beforehand the experiments and assess their actual feasibility. The necessary force at tool's tip has been evaluated both analytically, with a simplified approach based on a plane strain state, and numerically, by means of a commercial FEM code: different kinds of tool's trajectories have been generated by CAM programs, based on actual parts' geometries. A final assessment of whole cell layout and working has been performed by means of the IGRIP package, exploiting also the possibilities of the coordination with other external axes (e.g. a revolving table during flanging, a tool changing system, etc.) and its capability to generate the part program for the different commercial controllers. Several experimental tests have been performed in order to validate the complex methodology for system's design and prototyping and to study the many parameters playing a significant role in the process, as for instance: the different types of materials (e.g. AISI 304 and DC04 steels, copper), the number of axes of the task (3 or 5), the kind of interpolation between the points, the path imposed to the tool (e.g. depth first or breadth first), the size of punch tip, etc. Many tests have been performed on a mould specifically developed in-house for the execution system's trials, then a few tests have been performed on commercial components, on dies provided by a car manufacturers' supplier, with the execution of simple flanging operations too. It must be said that, even if the simulation environment proved to be powerful and reliable, the whole design process of the experiments seemed pretty complicated by the complexity of the used equipment: moreover, the use of more powerful robots, with larger workspaces would be desirable. In any case, in the end of the work, it is Authors' opinion that parallel robots are a viable alternative to CNC machines for the execution of incremental forming processes, especially if one is able to exploit the high versatility of the machine for further completing operations; more tests should be needed to completely assess the benefits of robotics, with the possible availability of more powerful machines, that are already available on the market. As for the system's design and prototyping tool that has been developed, it proved to be effective and reliable, even if more integration would be needed between the single software modules.


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    Titel :

    Robotised cell for the incremental forming of metal sheets


    Beteiligte:


    Erscheinungsdatum :

    2006


    Format / Umfang :

    8 Seiten, 19 Bilder, 12 Quellen



    Medientyp :

    Aufsatz (Konferenz)


    Format :

    Print


    Sprache :

    Englisch




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