New incremental forming tools and method

Patent metadata

Field	Value
Publication number	US-2019099799-A1
Application number	US-201716085185-A
Country	US
Kind code	A1
Filing date	Mar 22, 2017
Priority date	Mar 22, 2016
Publication date	Apr 4, 2019
Grant date	—

Abstract

An incremental forming tool of a sheet material has a tool holder having an axis and at least one tool rod mounted in the tool holder. The at least one tool rod may have variable shapes, lengths, diameters and radii such that the rotation of the at least one tool rod about the axis of the tool holder on the sheet material simulates an up and down, in and out, and/or side-to-side vibration motion.

First claim

1 . A method of incremental forming a sheet material, the method comprising the steps of:
providing a tool holder having an axis; providing at least one tool rod mounted in the tool holder, each tool rod having a height, a cross-sectional shape and a head; rotating the at least one tool rod about the axis of the tool holder, wherein the tool rod is shaped such that the rotation of the at least one tool rod on the sheet material simulates an up and down, in and out, and/or side-to-side vibration motion; applying the rotating tool rod to the sheet material; and forming the sheet material with the rotating tool rod.

2 . A method according to claim 1 , wherein the at least one tool rod includes more than one tool rod.

3 . A method according to claim 2 , wherein the height of one of the tool rods is different than another of the tool rods.

4 . A method according to claim 2 , wherein the radii of one of the tool rods is different than another of the tool rods.

5 . A method according to claim 2 , wherein the tool rods each have a different shape.

6 . A method according to claim 2 , wherein the tool rods are each disposed at a different distance from the axis of the tool holder.

7 . A method according to claim 1 , wherein the at least one tool rod includes two tool rods and a cross-sectional shape of each tool rod is circular and a head of each tool rod is hemispherical.

8 . A method according to claim 1 , wherein the at least one tool rod includes two tool rods, a cross-sectional shape of each tool rod being half-circular, a head of each rod being a half of a hemisphere, the two tool rods having different heights, and the two half-circular rods being mated together to form a cylindrical rod body with a step at the tip of the cylindrical rod body.

9 . A method according to claim 1 , wherein the at least one tool rod includes m tool rods, m being more than two, a cross-sectional shape of each tool rod being a one-m th division of a circle, a head of each rod being a one-m th of a hemisphere, each of the tool rods having a different height, and all of the tool rods being mated together to form a cylindrical rod body with one or more steps at the head of the cylindrical rod body.

10 . A method according to claim 1 , wherein the at least one tool rod has a polygonal cross section defining a plurality of forming ends each with an edge, the edges of each forming end having a different radius.

11 . A method according to claim 10 , wherein a central region at the head of the tool rod is in-plane with the forming ends.

12 . A method according to claim 10 , wherein a central region at the head of the tool rod is raised up or lowered down relative to the forming ends.

13 . A method according to claim 1 , wherein the at least one tool rod has a clover-shaped cross section having a plurality of petals, each petal having a length and a radius.

14 . A method according to claim 13 , wherein a length and/or radius of one of the petals is different than at least one other of the petals.

15 . A method according to claim 1 , wherein the tool rod has an oval-shaped cross section, one end of the oval shape has a larger radius than the other end.

16 . A method according to claim 1 , wherein the tool rod has a spiral shape.

17 . A method according to claim 1 , wherein the tool rod includes one or more protrusions at the surface of the head.

18 . A method according to claim 1 , wherein the head of the tool rod is shaped as a vertical sine wave or other wave shape.

19 . A method according to claim 18 , wherein a central region of the head is in plane with peaks of the wave.

20 . A method according to claim 18 , wherein a central region of the head is raised relative to peaks of the wave.

21 . A method according to claim 2 , further comprising the step of rotating each of the tool rods about a planet axis, while rotating the planet axis about the axis of the tool holder.

22 . A method according to claim 1 , wherein the at least one tool rod includes an offset from the axis of the tool holder and the offset is greater than zero.

23 . A tool used for incremental forming of a sheet material, comprising:
a tool holder having an axis; and at least one tool rod mounted in the tool holder, the at least one tool rod having height, a cross-sectional shape and a head, wherein the at least one tool rod is shaped such that a rotation of the at least one tool rod about the axis of the tool holder on the sheet material simulates an up and down, in and out, and/or side-to-side vibration motion.

24 . A tool according to claim 23 , wherein the at least one tool rod includes more than one tool rod.

25 . A tool according to claim 24 , wherein the height of one of the tool rods is different than another of the tool rods.

26 . A tool according to claim 24 , wherein the radii of one of the tool rods is different than another of the tool rods.

27 . A tool according to claim 24 , wherein the tool rods each have a different shape.

28 . A tool according to claim 24 , wherein the tool rods are each disposed at a different distance from the axis of the tool holder.

29 . A tool according to claim 23 , wherein the at least one tool rod includes two tool rods and a cross-sectional shape of each tool rod is circular and a head of each tool rod is hemispherical.

30 . A tool according to claim 23 , wherein the at least one tool rod includes two tool rods, a cross-sectional shape of each tool rod being half-circular, a head of each rod being a half of a hemisphere, the two tool rods having different heights, and the two half-circular rods being mated together to form a cylindrical rod body with a step at the tip of the cylindrical rod body.

31 . A tool according to claim 23 , wherein the at least one tool rod includes m tool rods, m being more than two, a cross-sectional shape of each tool rod being a one-m th division of a circle, a head of each rod being a one-m th of a hemisphere, each of the tool rods having a different height, and all of the tool rods being mated together to form a cylindrical rod body with one or more steps at the head of the cylindrical rod body.

32 . A tool according to claim 23 , wherein the at least one tool rod has a polygonal cross section defining a plurality of forming ends each with an edge, the edges of each forming end having a different radius.

33 . A tool according to claim 32 , wherein a central region at the head of the tool rod is in-plane with the forming ends.

34 . A tool according to claim 32 , wherein a central region at the head of the tool rod is raised up or lowered down relative to the forming ends.

35 . A tool according to claim 23 , wherein the at least one tool rod has a clover-shaped cross section having a plurality of petals, each petal having a length and a radius.

36 . A tool according to claim 35 , wherein a length and/or radius of one of the petals is different than at least one other of the petals.

37 . A tool according to claim 23 , wherein the tool rod has an oval-shaped cross section, one end of the oval shape has a larger radius than the other end.

38 . A tool according to claim 23 , wherein the tool r

Assignees

• Penn State Res Found

Inventors

• Roth John Timothy
• Grimm Tyler John
• Craig Glenn

Classifications

• B21D31/005 Primary

  Incremental shaping or bending, e.g. stepwise moving a shaping tool along the surface of the workpiece (B21D22/14 takes precedence) · CPC title