Design and Test of a Reconfigurable Forming Die

• Published in: Journal of manufacturing processes 2002, Vol.4 (1), p.77-85
• Main Authors: Haas, Edwin, Schwarz, Robert C., Papazian, John M.
• Format: Article
• Language: English
• Subjects: Accuracy; Aircraft; Design of Reconfigurable Tooling; Investigations; Laboratories; Machine tools; Metal Forming; Metalworking industry; Reconfigurable Dies; Sheet Metal Forming; Studies; Systems design; Tooling for Metal Forming
• ISSN: 1526-6125; 2212-4616
• DOI: 10.1016/S1526-6125(02)70134-5

Reconfigurable tooling is an attractive prospect for aerospace sheet metal forming because many different part shapes must be produced in small numbers. This paper describes the design and test of a particular type of “discrete-die” reconfigurable tool. The discrete-die concept involves using the ends of densely packed rod-shaped elements as the working surface of the die. The rod-shaped elements are reconfigured manually or automatically to change the shape of the die. Numerous mechanical schemes can be employed to move the elements: this paper describes the use of a shaft-driven lead screw concept. The input shaft turns continuously, and each pin's position is controlled by the engagement of an individual clutch. The required design parameters were developed using a combination of theory and experiment, and a laboratory-scale working prototype device was built and tested. The design parameters included an evaluation of the suitability of open-loop pin-position control based only on time, an evaluation of the torque capacity, engagement time, and reliability of the clutches, and the development of design loads. Experience in construction of the prototype showed that the design concept was sound but that significant enhancements to the control system would be required in a full-scale device.