Abstract
For structural assemblies that depend upon robotic incremental sheet forming (ISF) the rigidity, connectivity, customization and aesthetics play an important role for an integrated and accurate modeling process. Furthermore, it is critical to consider fabrication and forming parameters jointly with performance implications at material, element and structural scales. This paper briefly presents ISF as a method of fabrication, and introduces the context of structures where the skin plays an integral role. It describes the development of an integrated approach for the modelling and fabrication of Stressed Skins, an incrementally formed sheet metal structure. The paper then focus upon the use of prototypes and empirical testing as means to inform digital models about fabrication and material parameters including: material forming limits and thinning; the parameterisation of macro and meso simulations with calculated and observed micro behaviour; the organisation and extraction of toolpaths; and rig setup logics for fabrication. Finally, the validity of these models is evaluated for structural performance, and for geometric accuracy at multiple scales.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
Allwood, J, King, G and Duflou, J 2005, ‘A structured search for applications of the incremental sheet-forming process by product segmentation’, Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, vol. 219, pp. 239–244.
Amino, M, Mizoguchi, M, Terauchi, Y and Maki, T 2014, ‘Current Status of “Dieless” Amino’s Incremental Forming’, in Procedia Engineering: 11th International Conference on Technology of Plasticity, vol. 81, pp. 54–62.
Bagudanch, I, Centeno, G, Vallellano, C and Garcia-Romeu, M 2013, ‘Forming force in Single Point Incremental Forming under different bending conditions’, in MESIC, vol. 63, pp. 354–360.
Bailly, D, Bambach, M, Hirt, G, Pofahl, T, Herkrath, R, Heyden, H and Trautz, M 2014, ‘Manufacturing of Innovative Self-supporting Sheet-metal Structures Representing Freeform Surfaces’, in Procedia CIRP, vol. 18. pp. 51–56.
Bailly, D, Bambach, M, Hirt, G, Pofahl, T, Della Puppa, G and Trautz, M 2015, ‘Flexible Manufacturing of Double-Curved Sheet Metal Panels for the Realization of Self-Supporting Freeform Structures’, in Key Engineering Materials, vol. 639, pp. 41–48.
Filice, L, Fratini, L and Micari, F 2002, ‘Analysis of Material Formability’, Incremental Forming, CIRP Annals Manufacturing Technology, vol. 54, no. 1, pp. 199–202.
Jeswiet, J, Micari, Hirt, G, Bramley, A, Duflou, J and Allwood, J 2005, ‘Asymmetric Single Point Incremental Forming of Sheet Metal’, in CIRP Annals-Manufacturing Technology, vol. 54, no. 2. pp. 88–114.
Kalo, A and Newsum, M 2014, ‘An Investigation of Robotic Incremental Sheet Metal Forming as a Method for Prototyping Parametric Architectural Skins’ in Robotic Fabrication in Architecture, Art and Design 2014, pp. 33–49.
Nicholas, P, Stasiuk, D, Nørgaard, E, Hutchinson, C and Thomsen, MR 2015, ‘A Multiscale Adaptive Mesh Refinement Approach to Architectured Steel Specification in The Design Of A Frameless Stressed Skin Structure’ in Design Modelling Symposium: Modelling Behaviour, 2015.
Tabor, D 1951, Hardness of Metals, Clarendon Press, Oxford.
Tisza, M 2012, ‘General Overview of Sheet Incremental Forming’, Journal of Achievements in Materials & Manufacturing Engineering: vol. 55, no. 1, pp. 113–120.
Trautz, M and Herkrath, R 2009, ‘The application of folded plate principles on spatial structures with regular, irregular and free-form geometries’ in International Association for Shell and Spatial Structures (IASS), pp. 1019–1031.
Acknowledgements
This research was undertaken as part of the Sapere Aude Advanced Grant research project ‘Complex Modelling’, supported by The Danish Council for Independent Research (DFF). The authors would like to acknowledge the collaboration of Bollinger Grohmann consulting engineers, Daniel Piker and Will Pearson, the research departments DTU Mekanik and Monash Materials Science and Engineering, and the robot command and control software HAL.
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2016 Springer International Publishing Switzerland
About this chapter
Cite this chapter
Nicholas, P., Stasiuk, D., Nørgaard, E., Hutchinson, C., Thomsen, M.R. (2016). An Integrated Modelling and Toolpathing Approach for a Frameless Stressed Skin Structure, Fabricated Using Robotic Incremental Sheet Forming. In: Reinhardt, D., Saunders, R., Burry, J. (eds) Robotic Fabrication in Architecture, Art and Design 2016. Springer, Cham. https://doi.org/10.1007/978-3-319-26378-6_5
Download citation
DOI: https://doi.org/10.1007/978-3-319-26378-6_5
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-319-26376-2
Online ISBN: 978-3-319-26378-6
eBook Packages: EngineeringEngineering (R0)