Simulated 3-axis versus 5-axis Processing Toolpaths for Single Point Incremental Forming

Abstract

Accuracy and productivity of the parts manufactured by single point incremental forming (SPIF) are influenced by the proper selection of toolpaths. CAM software packages are often used for generating the toolpaths for the process. Literature survey have revealed that contour curves and spatial spirals are the most used toolpaths for SPIF. These toolpaths are generated using 3-axis approaches, meaning that the tool axis is maintained parallel to the vertical axis. The 3-axis approach was justified using 3-axis CNC milling machines as the main technological equipment for SPIF. However, nowadays, the wide spreading of both 5-axis CNC milling machines and industrial robots, with far superior kinematic capabilities justifies the research of more complex toolpaths for unfolding SPIF. In this paper, 5-axis toolpaths, where the tool is oriented by normal to machining surfaces are proposed and compared with 3-axis toolpaths, by means of simulation.