Abstract
Model predictive control (MPC) is an advanced control algorithm that has been successfully implemented in the on-line path optimization of computer-numerical-control (CNC) machines for performing single-pass incremental sheet forming (ISF) processes, aiming at precision enhancements of products. Multi-pass ISF technique is usually employed to manufacture parts with extremely large wall angles which cannot be achieved without failure using the single-pass ISF. However, existing studies show that the geometric precision of the products of multi-pass ISF is usually very poor, which has significantly hampered the widespread application of this technique in industry. In the present study, two control algorithms based on the MPC framework were proposed, targeting at achieving a more precise geometry of multi-pass ISF products. MPC-1 was an extension of the control algorithm for the single-pass ISF process reported in our previous work, and MPC-2 was developed for the first time. The developed MPCs were comparatively validated by a group of physical benchmark test. Compared to MPC-1, MPC-2 reduced the maximum geometric error in the wall, conjunction, and base zones on the same part by 26%, 51%, and 73%, respectively. The test results show that MPC-2 had a better performance in multi-pass ISF processes.
Similar content being viewed by others
Code availability
The code is not available.
References
Lu H, Liu H, Wang C (2019) Review on strategies for geometric accuracy improvement in incremental sheet forming. Int J Adv Manuf Technol 102(9-12):3381–3417. https://doi.org/10.1007/s00170-019-03348-3
Meier H, Buff B, Laurischkat R, Smukala V (2009) Increasing the part accuracy in dieless robot-based incremental sheet metal forming. CIRP Ann 58(1):233–238. https://doi.org/10.1016/j.cirp.2009.03.056
Mohanty S, Regalla SP, Daseswara Rao YV (2019) Robot-assisted incremental sheet metal forming under the different forming condition. J Braz Soc Mech Sci Eng 41(2). https://doi.org/10.1007/s40430-019-1581-6
Störkle DD, Möllensiep D, Thyssen L, Kuhlenkötter B (2018) Geometry-dependent parameterization of local support in robot-based incremental sheet forming. Procedia Manuf 15:1164–1169. https://doi.org/10.1016/j.promfg.2018.07.373
Li Y, Chen X, Zhai W, Wang L, Li J, Guoqun Z (2018) Effects of process parameters on thickness thinning and mechanical properties of the formed parts in incremental sheet forming. Int J Adv Manuf Technol 98(9-12):3071–3080. https://doi.org/10.1007/s00170-018-2469-9
Liu Z, Daniel WJT, Li Y, Liu S, Meehan PA (2014) Multi-pass deformation design for incremental sheet forming: analytical modeling, finite element analysis and experimental validation. J Mater Process Technol 214(3):620–634. https://doi.org/10.1016/j.jmatprotec.2013.11.010
Lu H, Kearney M, Li Y, Liu S, Daniel WJT, Meehan PA (2015) Model predictive control of incremental sheet forming for geometric accuracy improvement. Int J Adv Manuf Technol 82(9-12):1781–1794. https://doi.org/10.1007/s00170-015-7431-5
Li Y, Chen X, Liu Z, Sun J, Li F, Li J, Zhao G (2017) A review on the recent development of incremental sheet-forming process. Int J Adv Manuf Technol 92(5-8):2439–2462. https://doi.org/10.1007/s00170-017-0251-z
Liu F et al (2020) Modelling of the effects of process parameters on energy consumption for incremental sheet forming process. J Clean Prod 250. https://doi.org/10.1016/j.jclepro.2019.119456
Duflou JR et al (2008) Process window enhancement for single point incremental forming through multi-step toolpaths. CIRP Ann 57(1):253–256, 2008/01/01/. https://doi.org/10.1016/j.cirp.2008.03.030
Liu Z, Li Y, Meehan PA (2014) Tool path strategies and deformation analysis in multi-pass incremental sheet forming process. Int J Adv Manuf Technol 75(1-4):395–409. https://doi.org/10.1007/s00170-014-6143-6
Kim TJ, Yang DY (2000) Improvement of formability for the incremental sheet metal forming process. Int J Mech Sci 42(7):1271–1286. https://doi.org/10.1016/s0020-7403(99)00047-8
Skjoedt M, Silva MB, Martins PAF, Bay N (2009) Strategies and limits in multi-stage single-point incremental forming. J Strain Anal Eng Des 45(1):33–44. https://doi.org/10.1243/03093247jsa574
Liu Z, Li Y, Meehan PA (2013) Vertical wall formation and material flow control for incremental sheet forming by revisiting multistage deformation path strategies. Mater Manuf Process 28(5):562–571. https://doi.org/10.1080/10426914.2013.763964
Junchao L, Junjian S, Bin W (2013) A multipass incremental sheet forming strategy of a car taillight bracket. Int J Adv Manuf Technol 69(9):2229–2236, 2013/12/01. https://doi.org/10.1007/s00170-013-5179-3
He A, Kearney MP, Weegink KJ, Wang C, Liu S, Meehan PA (2020) A model predictive path control algorithm of single-point incremental forming for non-convex shapes. Int J Adv Manuf Technol. https://doi.org/10.1007/s00170-020-04989-5
Hirt G, Ames J, Bambach M, Kopp R, Kopp R (2004) Forming strategies and process modelling for CNC incremental sheet forming. CIRP Ann 53(1):203–206. https://doi.org/10.1016/s0007-8506(07)60679-9
Fu Z, Mo J, Han F, Gong P (2012) Tool path correction algorithm for single-point incremental forming of sheet metal. Int J Adv Manuf Technol 64(9-12):1239–1248. https://doi.org/10.1007/s00170-012-4082-7
Fiorentino A, Feriti GC, Giardini C, Ceretti E (2015) Part precision improvement in incremental sheet forming of not axisymmetric parts using an artificial cognitive system. J Manuf Syst 35:215–222. https://doi.org/10.1016/j.jmsy.2015.02.003
Fiorentino A, Giardini C, Ceretti E (2015) Application of artificial cognitive system to incremental sheet forming machine tools for part precision improvement. Precis Eng 39:167–172. https://doi.org/10.1016/j.precisioneng.2014.08.005
Mayne DQ, Rawlings JB, Rao CV, Scokaert POM (2000) Constrained model predictive control: stability and optimality. Automatica 36(6):789–814. https://doi.org/10.1016/s0005-1098(99)00214-9
Wang H, Duncan S (2011) Constrained model predictive control of an incremental sheet forming process. 2011 IEEE International Conference on Control Applications (CCA), 1288–1293
Lu H, Kearney M, Liu S, Daniel WJT, Meehan PA (2016) Two-directional toolpath correction in single-point incremental forming using model predictive control. Int J Adv Manuf Technol 91(1-4):91–106. https://doi.org/10.1007/s00170-016-9672-3
Lu H, Kearney M, Wang C, Liu S, Meehan PA (2017) Part accuracy improvement in two point incremental forming with a partial die using a model predictive control algorithm. Precis Eng 49:179–188. https://doi.org/10.1016/j.precisioneng.2017.02.006
He A, Wang C, Liu S, Meehan PA (2020) Switched model predictive path control of incremental sheet forming for parts with varying wall angles. J Manuf Process 53:342–355, 2020/05/01/. https://doi.org/10.1016/j.jmapro.2020.02.012
Allwood JM, Music O, Raithathna A, Duncan SR (2009) Closed-loop feedback control of product properties in flexible metal forming processes with mobile tools. CIRP Ann 58(1):287–290. https://doi.org/10.1016/j.cirp.2009.03.065
Bambach M (2010) A geometrical model of the kinematics of incremental sheet forming for the prediction of membrane strains and sheet thickness. J Mater Process Technol 210(12):1562–1573. https://doi.org/10.1016/j.jmatprotec.2010.05.003
Funding
The authors acknowledge Queensland Government, Boeing Research & Technology - Australia, The University of Queensland, and QMI Solutions for the support and collaboration through the Advanced Queensland Innovation Partnerships Project 2016000418. The first author acknowledges the University of Queensland for financial support.
Funding
The data is not available.
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
Conflict of interest
The authors declare no competing interests.
Additional information
Publisher’s note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
He, A., Wang, C., Liu, S. et al. On-line autonomous path optimization for multi-pass incremental forming using model predictive control. Int J Adv Manuf Technol 116, 3339–3353 (2021). https://doi.org/10.1007/s00170-021-07616-z
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-021-07616-z