Development of a kinematic model for a free kinematic forming process to compute the tool trajectory

• Published in: Proceedings in applied mathematics and mechanics 2024-10, Vol.24 (3), p.n/a
• Main Authors: Ekanayaka, Virama, Hürkamp, André, Dröder, Klaus
• Format: Article
• Language: English
• ISSN: 1617-7061; 1617-7061
• DOI: 10.1002/pamm.202400193

In the production of hybrid composites made of thermoplast and metal sheets, certain limitations in the linear forming process can be overcome through a free kinematic forming process. This process involves distributing the thermoplast press mass using a tumbling or cyclic rolling movement of the forming tool. Due to this special kinematics, only a small part of the tool is ever in engagement with the workpiece, so the component is formed incrementally. Therefore, the final geometry does not have to be created in one stroke but can be carried out step by step in several partial strokes. In order to determine the optimal trajectory of the forming tool, the kinematic interplay between the workpiece, forming tool, and toolpath should be numerically captured in a mathematical model. The specific toolpath depends on the component being formed, as well as the actual geometry of the forming tool. In this research, the free kinematic forming process is modeled and the optimal toolpath is determined using a genetic algorithm. The optimal toolpath enables a uniform distribution of the thermoplast to a specified thickness and collisions between the upper and lower tool are avoided. This enables key insights into the free kinematic forming process and opens up further avenues of research for this innovative and future‐oriented manufacturing concept.