Die-less Sheet Metal Forming (27097)

INVENTION: Without the need of a die, the invention forms sheet metal through a new technique known as Double Sided Incremental Forming (DSIF). Die-less, incremental forming methods like DSIF have been used to cost-effectively form prototype and low-volume production parts. In contrast to other “3D-forming methods,” such as roll-forming, hydroforming and explosive forming, incremental methods provide significant forming flexibility while keeping capital cost low.

Advantages are as follows:

Less Costly: Partially or totally eliminates dies Faster: Enables rapid prototyping and faster production of small lots Standard Operation: Uses standard CNC equipment Simple: Is simple and very safe to use Saves Space: Requires less space More Intricate: Handles complex shapes

The below Figures show the concept, the tool setup, and a part formed using DSIF (Note that the setup is shown in the passive mode, where one of the tools follows the trajectory of the other tool. DSIF can also be setup with two totally independent tools). Die-less incremental forming methods like DSIF can commonly be used to form a local shape in a part, with standard techniques used to form the remainder of the part. Alternately, DSIF can be used to form the entire part.

Current die-less incremental forming methods use single point incremental forming (SPIF). What distinguishes DSIF is that it can produce geometrical features on either side of the plane of a sheet without needing to change the setup. This not only saves in setup time, but it enhances reliability in that top and bottom side geometries are formed together. DSIF better controls local part geometry and material thickness than SPIF and can apply greater compressive stress, which leads to better formability. It can be applied to work harden materials.

Northwestern University seeks a commercial partner(s) to utilize this invention and assist in some fashion with its commercialization. We look forward to investigating DSIF as a viable solution for some of your particular part forming problems.

Inventor(s): J. Cao, V. Reddy and Y. Wang

Type of Offer: Licensing



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