Virtual Sensor-Based Geometry Prediction of Complex Sheet Metal Parts Formed by Robotic Rollforming

Sheet metal parts can often replace milled components, strongly improving the buy-to-fly ratio in aeronautical sector. However, sheet forming of complex traditionally requires expensive tooling, which is usually prohibitive for low manufacturing rates. To achieve precise parts, non-productive and cost-intensive geometry straightening processes are additionally required after forming. Rollforming a possible technology producing profiles at large For rates, robotic rollforming be an interesting option, significantly reducing investment cost higher times while keeping high process flexibility. Forming performed incrementally by single roller set moved robot along predefined bending curves. The present work’s contribution to overall solution development intelligent algorithm calculate based on reaction forces. This information in-process geometric distortion correction. Reaction forces torques acquired during process, calculated artificial intelligence (AI) applied that information. paper describes AI this virtual sensing system.