• Journal of the Korean Society for Precision Engineering
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• v.23 no.2 s.179
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• pp.191-198
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• 2006

Dieless CNC forming is an innovative technology which can form various materials with complex shape by numerically controlled incremental forming process. In this paper, a method of NC tool path generation based on an STL file for dieless CNC forming is proposed. Tool trajectory adopts the principle of layered manufacturing in rapid prototyping technology, but it is necessary to consider STL offset because of the ball shaped tool with a radius. Vertex offset method which enables to compute offset STL directly is engaged for STL offset. The offseted STL is sliced by cutting planes to generate contouring tool path. Algorithm is implemented on a computer and experimented on a dieless CNC forming machine to show its validity.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2004.10a
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• pp.405-408
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• 2004

The sheet parts are formed with dies conventionally. But this conventional forming process is not suited to small volume and varied production for the reason of high cost. For the solution of this problem, a new forming process, which is called CNC incremental sheet forming, is being introduced. This process can form sheet parts without die, and is very well suited to small volume and varied production in space flight and automobile. In this paper, dieless CNC forming system based on a machining center is developed. A special device to grasp and pull the blank sheet built in the machining center and tool path generation S/W from STL file of 3-D model are developed. Several sheet parts are incrementally formed to verify the effectiveness of the developed system.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.10a
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• pp.184-187
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• 2004

The sheet parts are formed with dies conventionally. But this conventional forming process is not suited to small volume and varied production for the reason of high cost. For the solution of this problem, a new forming process, which is called CNC incremental sheet forming, is being introduced. This process can form sheet parts without die, and is very well suited to small volume and varied production in space flight and automobile. In this paper, dieless CNC forming system based on a machining center is developed. A special device to grasp and pull the blank sheet built in the machining center and tool path generation S/W from STL file of 3-D model are developed. Several sheet parts are incrementally formed to verify the effectiveness of the developed system.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.6 no.4
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• pp.36-43
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• 2007

Dieless CNC forming is an innovative technology which can form various materials with complex shape by numerically controlled incremental forming process. In order to apply the technology to industrial parts, however, many problems such as spring-back, rising of material, and trimming difficulty must be solved. In this paper a new dieless CNC forming method to improve forming quality is proposed, which consists of how to modify its original shape in CAD and how to generate its CNC tool path in CAM. The effectiveness of the proposed procedures is tested with a brake dust shield of a vehicle. The results shows that the method proposed enhances the forming quality up to 48% compared to traditional method.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.1753-1756
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• 2005

The sheet parts are formed with dies conventionally. But this conventional forming process is not suited to small volume and varied production for the reason of high cost. For the solution of this problem, a new forming process, which is called CNC incremental sheet forming, is being introduced. This process can form sheet parts without die, and is very well suited to small volume and varied production in space flight and automobile. In this paper, dieless CNC forming system based on a machining center is developed. A special device to grasp and pull the blank sheet built in the machining center and tool path generation S/W from STL file of 3-D model are developed. Several sheet parts are incrementally formed to verify the effectiveness of the developed system.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.05a
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• pp.379-382
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• 2007

The MEMS (Micro Electro Mechanical Systems) process is used in a micro/nano pattern manufacturing method. This method is based on the lithography technology. But the MEMS process has some problems such as complicated process, long processing time and high production costs. Many researchers are doing research in substitute manufacturing method to work out a solution to these problems. In this paper, we apply a dieless incremental forming technology to a substitute method of MEMS process. This dieless forming technology is using in the commercial scale sheet forming such as a prototype of automobile sheet parts. 5-axes CNC (Computerized Numeric Control) method are applied in this system to get a micro-scale dieless forming results. These 5-axes system are composed of precision AC servo motor stages (4-axes) and PZT actuator (1-axis). A PZT actuator is used in a precision actuating axis because it can be operated in the nano scale stroke resolution. This micro dieless incremental forming system has the advantage of minimization in manipulating distance and working space. As equipment and tools become smaller in size, minute inertia force and high natural frequency can be obtained. Therefore, high precision forming performance can be obtained. This allows the factory to quickly provide the customer with goods because the manufacturing system and process are reduced. To construct this micro manufacturing system, many technologies are necessary such as high stiffness frame, high precision actuating part, structural analysis, high precision tools and system control. To achieve the optimal forming quality, the micro dieless forming system is designed and made with high stiffness characteristic.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2006.05a
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• pp.529-530
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• 2006

Manufacturing industry is changing rapidly. Prototyping with rapid manufacturing is a part of every business in many companies and prototypes are used efficiently as a part of the production development process. Sheet metal forming has traditionally been a technology area where prototyping has been extremely expensive and efficient options for low volume have been limited. This paper describes the process for incremental sheet forming technologies to make the prototype for a brake dust shield of vehicles, which includes the remodeling method to make a base mold and tool path for sheet metal forming and 5-axes laser cutting machine to trim the prototype product.