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The purpose of this paper is to investigate usage of fused deposition modeling (FDM)-based sheet metal tooling for small lot productions as a real case. FDM-based sheet metal tooling was used for stamping prototype parts for two different materials to evaluate dimensional conformance.

The experimental process of data capture used the following steps: sheet metal parts were stamped and optically scanned at every 10th interval for both DC04 and S355MC material. FDM-based upper and lower dies were optically scanned at 1st, 51st and 101st intervals. Dimensional conformance analyses were carried out by using scanned data to evaluate the behavior of FDM dies against DC04 and S355MC materials in terms of geometric deviation.

Satisfactory results were obtained for DC04 material by using FDM-based tooling, and overall deviation was at an acceptable level in terms of production tolerance. S355MC material is harder than DC04 and results were not convenient in terms of tolerance range. Geometric deviation of FDM dies was slightly increased and after the 50th part, increased drastically due to squeezing of FDM layers. Experiments showed that this method can be used for DC04 material and up to 100 parts can be stamped within the tolerance range. Using FDM-based sheet metal tooling, product development phase can be shortened in terms of leading time.

This paper presents a study to create an alternative tooling method to shorten product cycle and product development phase by integrating rapid tooling methods to low-volume production.

To study the influence of process and product parameters on the properties of products in incremental sheet metal‐forming; to create models for process optimisation and to introduce an approach to incremental forming process optimisation.

A new flexible sheet metal‐forming technique, incremental forming, has been studied. The technique can be viewed as a rapid prototyping/manufacturing technique for sheet metal parts. To analyse the process, an experimental study and finite element analysis were performed. For the optimal design of incremental forming process non‐linear mathematical programming was used. To estimate the limitations and main parameters of the process, a complex model was developed.

Introducing optimisation procedures for the incremental forming process allows users to increase productivity and to assure quality.

As finite element analysis of the process is time‐consuming in real life situations, a future study should include creating analytical models for process modelling.

The described approach can be used in practice to improve competitiveness of companies producing sheet metal prototypes.

This paper offers guidelines for shortening processing time of sheet metal prototypes for engineers and researchers. The optimisation that is based on experimental/theoretical/numerical models of incremental forming process has not been covered before in the scientific literature.

The paper aims to design a process to mechanize traditional chasing and repoussé which is the art of creating an artistic pattern on a sheet metal by making high and low points through utilization of hammer and chisel. In scientific literature, it is a kind of incremental sheet metal forming.

In the designed process, a magnetic actuator is used as a hammer which converts electric energy into kinetic reciprocal impact energy, and hammering sequence is completely controlled via the designed software. The sheet is bound not to move easily. Then, a hammering mechanism is connected to the numerical control machine. As the magnetic hammer is moved gradually along the defined path, the sheet is chased gradually by controlling the consecutive impacts. Different methods of test sheet entanglement are also discussed to reduce noise and undesired deformations of sheet, and indents are also clarified.

The designed mechanism enables the user to form desired art patterns faster with more precision via the automated process. The hammering sequence is controlled via computer successfully. The designed magnetic actuator could be commercialized easily. Experiments show that the pitch under sheet is the best. Typical art patterns are chased successfully.

In incremental sheet metal punching, there was no control on hammering sequence before. In this process, the designed magnetic hammer is quite controllable. Also, it is easily attached to the computerized numerical control (CNC) and is suitable for commercial use. Furthermore, the stuff under sheet was not taken into consideration before.

It is now well‐known that laser forming offers considerable potential for rapid prototyping and manufacture of sheet metal components. However, a problem with the technique to date has been the generally poor repeatability of the process as a whole on a run‐to‐run or‐day‐to‐day basis. Efforts to rectify the problem by careful selection and pre‐setting of the process parameters, based on empirical data, have proved unsatisfactory due to the inherent variability of the laser system. Elimination of the variability would require conditions which would be impractical for production situations. In order to overcome this difficulty a closed loop control system based on monitoring component deformations, as they approach target values, has been developed. In response to the deformation data, available at each forming pass, the forming parameters are adjusted so that forming continues at an optimum rate to a predetermined tolerance. Discusses the production of laser‐formed components and shows how the implementation of a feedback control system can negate the inevitable process variability, thereby significantly aiding the efficient and accurate production of components.

Report from a recent conference held in Italy and organised by the Rapid Prototyping Research Group at the University of Nottingham. Papers were presented on a wide variety of subjects including stereolithography, selective laser sintering, laser forming, fused deposition modelling, three‐dimensional printing, CAD and data transfer and rapid tooling. Tooling was one of the key topics during the three‐day event.

Examines the developing uses of off‐line programming (OLP) in the automotive industry, particularly in the areas of robot welding and robot painting of vehicle bodies. States that this is due to the development of graphical simulation tools and outlines their role in “right first time” policies. Looks at applications of OLP at Volvo, Capponi Alesina (Fiat’s largest, painting subcontractor) and Applied Manufacturing Technologies, a US manufacturing systems design house. Describes the use of OLP in painting machines and truck painting, and in spot welding truck bodies.

In manufacturing, dedicated machine tools and flexible machine tools are failing to satisfy the ever-changing manufacturing demands of short life cycles and dynamic nature of products. These machines are limited when new product designs are introduced. The solution lies in developing responsive machines that can be adjusted or be changed functionally when these change requirements arise. These machines are reconfigurable machines which are becoming the new focus, as they rapidly respond to product variety and volume changes. A sheet metal working machine known as a reconfigurable guillotine shear and bending press machine (RGS&BPM) has been developed. The purpose of this paper is to present a methodology, function-oriented design approach (FODA), which was developed for the design of the RGS&BPM.

The design of the machine is based on the six principles of reconfigurable manufacturing systems (RMSs), namely, modularity, scalability integrability, convertibility, diagnosability and customisability. The methodology seeks to optimise the design process of the RGS&BPM through a design of modules that make up the machine, enable its conversion and reconfiguration. The FODA is focussed on function identification to select the operational function required. Two main functions are recognised for the machine, these being cutting and bending; hence, the design revolves around these two and reconfigurability.

The developed design methodology was tested in the design of a prototype for the reconfigurable guillotine shear and bending press machine. The prototype is currently being manufactured and will be subjected to functional tests once completed. This paper is being presented not only to present the methodology by to show and highlight its practical applicability, as the prototype manufacturers have been enthusiastic about this new approach.

The research was limited to the design methodology for the RGS&BPM, the machine which has been designed to completion using this methodology, with prototype being manufactured.

This study presents critical steps and considerations in the development of reconfigurable machines. The main thrust being to explore the best possibility of developing the machines with dual functionality that will assist in availing the technology to manufacturer. As the machine has been development, the success of the design can be directly attributed to the FODA methodology, among other contributing factors. It also highlights the significance of the principles of RMS in reconfigurable machine design.

The RGS&BM machine is an answer for the small-to-medium enterprises (SMEs), as the machine replaces two machines with one, and the methodology ensures its affordable design. It contributes immensely to the machine availability by eliminating trial and error approaches.

This study presents a new approach to the design of reconfigurable dual machines using principles of RMS. As the targeted market is the SME, it is not limited to that as any entrepreneur may use the machine to their advantage. The design methodology presented contributes to the body of knowledge in dual reconfigurable machine tool design.

This article contains short accounts of some of the means adopted by Glenn L. Martin to build their first post‐war air liner, the 2–0–2, without the prior building of a prototype. Although this commendable effort to hasten into service a replacement for the Dakota eventually resulted in the production of an excellent air liner, we understand that it is an experiment that is not likely to be repeated. As was almost invariably the case during the war when a prototype was dispensed with, the delay in ironing out the teething troubles (which always seemed to be more than usual in such cases) and modifying the machines on the line was greater than that between the prototype and production.—EDITOR.

The main aim of this study is to generate curved-form cut on the edge of an adaptive layer. The resulting surface would have much less geometry deviation error and closely fit its computer aided design (CAD) model boundary.

This method is inspired by the manual peeling of an apple in which a knife's orientation and movement are continuously changed and adjusted to cut each slice with minimum waste. In this method, topology and geometry information are extracted from the previously generated adaptive layers. Then, the thickness of an adaptive layer and the bottom and top contours of the adjacent layers are fed into the proposed algorithm in the form of the contour and normal vector to create curved-form sloping surfaces. Following curved-form adaptive slicing, a customized machine path compatible with a five-axis abrasive waterjet (AWJ) machine will be generated for any user-defined sheet thicknesses.

The implemented system yields curved-form adaptive slices for a variety of models with diverse types of surfaces (e.g. flat, convex, and concave), different slicing direction, and different number of sheets with different thicknesses. The decrease in layer thickness and increase of the number of the sloped cuts can make the prototype as close as needed to the CAD model.

The algorithm is designed for use with five-axis AWJ cutting of any kind of geometrical complex surfaces. Future research would deal with the nesting problem of the layers being spread on the predefined sheet as the input to the five-axis AWJ cutter machine to minimize the cutting waste.

The algorithm generates adaptive layers with concave or convex curved-form surfaces that conform closely to the surface of original CAD model. This will pave the way for the accurate fabrication of metallic functional parts and tooling that are made by the attachment of one layer to another. Validation of the output has been tested only as the simulation model. The next step is the customization of the output for the physical tests on a variety of five-axis machines.

This paper proposes a new close to CAD design sloped-edge adaptive slicing algorithm applicable to a variety of five-axis processes that allow variable thickness layering and slicing in different orientations (e.g. AWJ, laser, or plasma cutting). Slices can later be bonded to build fully solid prototypes.

To design a reconfigureable flexible fixture for the assembly of a set of sheet metal automotive body parts. Reconfigureable fixturing permits different parts to be grasped for assembly by a fixture without the need to conduct costly redesign and fabrication of hardware fixtures, which is an industry standard in widespread use in industry. While somewhat more complex than fixtures in current use, reconfigureable fixtures provide one solution to the problem of costly redesign of fixtures due to changes in dimensions, or geometry of parts to be assembled.

We propose a novel reconfigureable fixture for robotic assembly of a number of different parts. Motivated by the marine organism, O. vulgaris, commonly referred to as an octopus, which grasps different objects or prey using suction cups, the proposed fixture has three fingers, each equipped with a suction cup, to facilitate the grasping process and increase grasp flexibility. Using this design approach, the fixture is sufficiently general in design to grasp several different parts. To position the suction cups located on the flexible fixture, two linkage‐based mechanisms are employed. Pneumatic cylinders and electric motors are used as actuators. A prototype flexible fixture has been built and experimental results with this prototype confirm the effectiveness of the proposed flexible fixture. Software has been developed to calculate the relative positions and angles in the mechanism as required for reconfiguration.

The proposed reconfigureable fixture, used as an end‐of‐arm tool, permits each of a set of four sheet metal parts to be successfully grasped permitting assembly of these four components, in a robotic assembly work cell.

The proposed flexible fixture is a simple proof‐of‐concept device that is suitable for a laboratory setting. We do not consider part localization of parts when grasped by the reconfigureable fixture.

Assembly operations, in industrial manufacturing operations, are typically heavily reliant on hardware fixtures devices to orient and clamp parts together during assembly operations. While of great importance in such operations, hardware fixtures are very costly to design and build. Further, fixtures are designed for use with parts of specific dimensions and geometry, hence cannot be used to grasp or orient parts with even very small differences in dimensions or geometry. Typically, if parts with different dimensions or geometry are to be assembled, new hardware fixtures must be designed and manufactured to grasp and orient these parts. This lack of flexibility leads to substantial manufacturing costs associated with fixturing. Reconfigureable fixtures permit parts with different geometries to be grasped and oriented for assembly.

Reconfigureable fixtures for use in the automotive manufacturing sector is an important development due to the highly competitive nature of this industry. Rapid introduction of new models of vehicles is greatly facilitated through the use of reconfigureable fixtures which can be reprogrammed to grasp parts of different geometries required for new vehicle models.