Capabilities of robot-based double-sided incremental hot-forming of fiber-reinforced thermoplastics

Thermoplastic composites are gaining interest for their good recyclability, in addition to their mechanical performance and light weight potential. However, conventional molding processes for thermoplastic composites, such as hot pressing, require full-surface, geometry-specific molding tools and are therefore associated with high investment costs and long lead times until production can start. This is a strong drawback for manufacturing of small series, prototypes or in case of geometry changes. A promising flexible alternative is incremental forming, where geometry-agnostic tool tips exert local force to successively form the part. This allows for the economical and quick production of small part quantities. This work investigates the capabilities of a novel double sided incremental hot-forming process that employs two cooperating robots to drape a heated organosheet into the targeted shape. The process is assessed regarding mechanical performance, geometric accuracy and economic efficiency. The analysis shows that the presented process is capable of producing a wide variety of geometries with viable accuracy and good mechanical performance. The economic assessment reveals a clear advantage in both lead time as well as per part cost for small lot sizes.

Subjects

dieless robotic manufacturing

fiber reinforced thermoplastic composites

incremental thermoforming

DDC Class

629.13: Aviation Engineering

Funding(s)

Entwicklung eines Prozesses zur inkrementellen, formwerkzeuglosen Umformung faserverstärkter Halbzeuge, sowie Umsetzung einer digitalen Prozesskette zur Planung- und Steuerung

Options

Capabilities of robot-based double-sided incremental hot-forming of fiber-reinforced thermoplastics