System and method for accumulative double sided incremental forming

A system comprising:

• a processor;
• the processor comprising;
• an input module configured to obtain a three-dimensional model of a component to be formed from a deformable sheet by first and second tools that engage corresponding first and second opposite sides of the sheet and that move relative to the sheet to deform the sheet, the three-dimensional model including plural three-dimensional features that protrude from at least one of the first side or second side of the sheet;
• an equalization module configured to an incremental depth at which the at least one of the first and second tools move toward or away from the sheet to form the features in the sheet, the incremental depth based on a number of curves formed by intersections of the model with a set of planes oriented parallel to the sheet;
• a sorting module configured to associate at least a first set of the curves formed by the intersections of the model with the planes with a first feature of the features in the model and a second set of the curves formed by the intersections of the model with the planes with a different, second feature of the features in the model;
• a point generation module configured to determine one or more toolpaths that the first and second tools follow in order to deform the sheet into the component, the point generation module configured to determine segments of the model that are disposed between neighboring planes in the set of planes and to determine one or more helical curves extending along the segments from an internal area of the sheet toward outer boundaries of the sheet;
• and
• a path writing module configured to identify contact points along the one or more toolpaths and directions in which the first and second tools are to move along the one or more toolpaths, the contact points being locations where the first and second tools are to engage and deform the sheet to form the component from the sheet based on the model, wherein the path writing module determines the contact points and the directions such that the first and second tools move along the one or more toolpaths in an in-to-out direction laterally along the sheet;
• wherein the tools of the system engage the sheet to deform the sheet into the component defined by the model.

A method for obtaining a three-dimensional model of a component formed from a deformable sheet having first and second opposite sides and including plural three-dimensional features that protrude from at least one of the first side or second side of the sheet, the method comprising:

• a processor performing:
• engaging the corresponding first and second opposite sides of the deformable sheet with first and second tools and moving said tools relative to the sheet to deform the sheet;
• wherein the first and second tools are engage the sheet to deform the sheet into the component defined by the model;
• moving at least one of the first and second tools toward or away from the deformable sheet to an incremental depth to form the features in the sheet, the incremental depth being based on a number of curves formed by intersections of the model with a set of planes oriented parallel to the sheet;
• associating at least a first set of the curves formed by the intersections of the model with the planes with a first feature of the features in the model and a second set of the curves formed by the intersections of the model with the planes with a different, second feature of the features in the model;
• determining one or more toolpaths that the first and second tools follow in order to deform the sheet into the component by determining segments of the model that are disposed between neighboring planes in the set of planes and determining one or more helical curves extending along the segments from an internal area of the sheet toward outer boundaries of the sheet;
• and
• identifying contact points along the one or more toolpaths and directions in which the first and second tools are to move along the one or more toolpaths, the contact points being locations where the first and second tools are to engage and deform the sheet to form the component from the sheet based on the model, wherein the contact points and the directions are determined such that the first and second tools move along the one or more toolpaths in an in-to-out direction laterally along the sheet.