Development of an actuation system for a specialized fixture: providing two degrees of freedom for single point incremental forming

Abstract

In this thesis, an actuation system is developed for a Two-Axis Gyroscopic (TAG) adapter. This adapter is a fixture with two auxiliary axes which is used for the Single Point Incremental Forming (SPIF) technique to enhance a three-axis mill to have five-axis capabilities. With five-axis mill capabilities, variable angles between line segments of the toolpath and the tool can be obtained. To achieve specialized angles between a line segment and the SPIF tool, the sheet is rotated. Inverse kinematic equations for the TAG adapter are derived to calculate the required rotations for the TAG adapter’s auxiliary axes for a line segment of a toolpath. If the next line segment requires a different orientation of the sheet, the sheet is rotated while the tool follows the rotation of the sheet to maintain its position at the connecting point of the line segments of the toolpath. Five equations of motions are derived to calculate the three translations of the mill and two rotations of the TAG adapter’s frames, during forming. A toolpath execution algorithm is implemented in MATLAB which uses the five equations of motion to execute a toolpath. The algorithm generates an array of data points that can be used by a Computer Numerically Controlled (CNC) machine to follow a desired path. A visual representation for the execution of the toolapth is implemented in MATLAB and is used to illustrate the successful completion of a toolpath. A computer controlled motor system is selected and tested in this thesis which will ultimately be integrated with a worm gear system and a CNC machine to develop a full CNC actuation system.