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Fixturing for Double-Sided Incremental Forming Machine

As a generous donation to the University of New Hampshire from Ford Motor Company and Ingersoll Production Systems, the Double-Sided Incremental Forming (DSIF) machine is being used as a resource to train and educate UNH graduate and undergraduate students. The DSIF machine’s current focus is to conduct research related to producing individually designed biomedical trauma hardware for hospital patients with severely fractured bones. Incremental forming is a manufacturing technique where a piece of sheet metal is secured by a forming frame and is formed into the final workpiece by a series of small incremental deformations; however, the current frames being utilized are too large leading to imperfect parts and wasted material. The purpose of this project is to design, manufacture, and implement a new sheet metal frame that will reduce the operating window to allow for more reliability when forming smaller parts. The team accomplished this objective by designing the Revision 4 (Rev 4) Cross and Sub-frame Fixturing through computer aided simulations and multiple generational improvements. The new Rev 4 design is more compartmental, compact, and versatile compared to its predecessors. The internal sub-frames that can be removed allow for post forming condition techniques to occur, such as heat treating. The new fixturing will allow less material to be wasted and will provide a strong and clean work area when manufacturing biomedical trauma products.

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