Multi-stage incremental sheet forming systems and methods
AssigneeThe Boeing Company
InventorMichael C. Elford
Life of this patent
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Abstract
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.
Claims22
A multi-stage incremental sheet forming system, comprising:
- a forming tool;
- and
- at least one control unit in communication with the forming tool,
- the at least one control unit configured to determine a convex hull of a target structure to be formed by the forming tool,
- the at least one control unit 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, and
- the at least one control unit 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, wherein the second tool path differs from the first tool path.
A multi-stage incremental sheet forming method, comprising:
- determining, by at least one control unit, a convex hull of a target structure to be formed by a forming tool;
- operating, by the at least one control unit, 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;
- and
- operating, by the at least one control unit, 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, wherein the second tool path differs from the first tool path.
A multi-stage incremental sheet forming system, comprising:
- a forming tool;
- at least one control unit in communication with the forming tool;
- and
- a structure database in communication with the at least one control unit, wherein the structure database stores target data including information regarding a geometric representation of a target structure and one or more inward features of the target structure, wherein the one or more inward features comprise one or more of at least one indentation, at least one cavity, at least one divot, at least one channel, at least one recess, at least one groove, at least one crease, at least one pocket, at least one inset, or at least one hole,
- the at least one control unit comprises:
- a convex hull determination module configured to determine a convex hull of a target structure to be formed by the forming tool;
- a convex hull tool path generation module configured to one or both of operate or output instructions for operating the forming tool according to a Z level 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, wherein the intermediate structure is devoid of the one or more inward features;
- and
- a target structure tool path generation module configured to one or both of operate or output instructions for operating the forming tool according to a lace tool path in relation to the intermediate structure to form the one or more inward features into the intermediate structure to form the target structure.
Dependencies are inferred from the claim text.