Closed Loop 3-Dimensional Laser Forming of Developable Surfaces

Thermal Forming, F Vollertsen, T Seefeld [Eds] , Strahltechnik Volume 26,
BIAS Verlag, Bremen, 2005, ISBN: 3-933762-16-2

Abstract: 2-Dimensional laser forming can currently control bend angle, with reasonably accurate results, in various materials including aerospace alloys. However, this is a different situation for 3-Dimensional laser forming. To advance this process further for realistic forming applications and for straightening and aligning operations in a manufacturing industry it is necessary to consider larger scale controlled 3D laser forming. The work presented in this paper uses a predictive and adaptive approach to control the 3D laser forming of Mild Steel sheet into a desired developable surface. This is defined as a surface that can be unfolded onto the plane without stretching or tearing. Key to the control of the process was the development of a predictive model to give scan strategies based on a required geometry. The forming rate and distribution of the magnitude of forming across the surface were controlled by the process speed. When the geometry is not formed within one pass, an incremental adaptive approach is used for subsequent passes, utilising the error between the current and desired geometry to give a new scan strategy, thus any unwanted distortion due to material variability can be accounted for.

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