Dyna-Die: Towards Full Kinematic Incremental Forming

This article focuses on the realization of a simple and kinematic tool setup for incremental sheet metal forming. It allows achieving a similar geometrical accuracy like a full specific support, but minimizes the tool setup and increases the process flexibility at the same time. In incremental sheet metal forming different process variants are in use. The simplest one is the single point incremental forming process which works with a single forming tool and does not require any support. The partially supported incremental forming process uses a simple tool setup for a static support of the sheet when forming only in local areas. In the fully supported incremental forming process a specific die is used which includes the geometry of the part to be manufactured. Here, a good geometrical accuracy can be achieved, but expensive and specific tools are needed for the support. In the full kinematic incremental forming process both the forming tool and the supporting tool move synchronously in three axes. This process is very flexible regarding the part geometry and promises a good accuracy. However, the mechanical setup is very complex and requests a specialized machine. The setup described in this article includes a kinematic support which can be mounted on a conventional milling machine. The presented dynamic support consists of an exchangeable support tool, which is fixed on a rotating plate. During the incremental forming process the dynamic support moves synchronously with the forming tool. This way, a flexible forming with simple tools and low costs is realized. The parts manufactured by the Dyna-Die have been compared to parts which were produced using a full and a partial static support as well as without any support. The discussion of the results completes this contribution.