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ROBOFORMING: The Future of Metalworking? (I Had NO IDEA This Was Possible) - Smarter Every Day 290

SmarterEveryDay・29 minutes read

Destin from Smarter Every Day explores incremental sheet forming for small-scale production, showcasing Roboforming by Machina Labs in L.A. using specialized touch techniques on metal sheets. The process eliminates costly molds, allowing for faster production, but requires precise calibration to maintain accuracy under load and considers factors like sheet deflection and spring back for accurate part formation.

Insights

  • Incremental sheet forming is advantageous for quick part iteration in small-scale production, eliminating the need for costly molds and allowing faster production after design finalization.
  • The precision required in Roboforming by Machina Labs involves intricate math, calibration, and continuous feedback mechanisms to anticipate and correct for robot and sheet deflection, ensuring accurate metal forming despite complexities like backlash in gear trains and rigidity considerations in robot arms.

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Recent questions

  • What is incremental sheet forming?

    Incremental sheet forming is a manufacturing process that allows for quick part iteration, beneficial for small-scale production or development. It involves shaping metal sheets gradually to create unique geometries without the need for costly molds, enabling faster part production after design completion.

  • How does Roboforming work?

    Roboforming is a method of shaping metal through specialized touch techniques showcased by Machina Labs in L.A. It involves using end effectors on KUKA and Phanax robots to deform strong metal sheets, similar to a potter shaping clay. The robots apply forces up to 20,000 Newtons with precise calibration to maintain accuracy under load, ensuring accurate metal forming despite robot deflection.

  • What role do actuators play in metal forming?

    Actuators play a crucial role in metal forming by transmitting forces down to the base of a robot, determining torque based on the offset between force and actuator. Imperfections like backlash in gear trains within actuators can affect motion control, requiring intricate math and calibration to anticipate and adjust for robot and sheet deflection during forming.

  • How do robots ensure accuracy in metal forming?

    Robots ensure accuracy in metal forming by utilizing continuous feedback and correction mechanisms to maintain precision despite changing forces. Different poses and optimization strategies enhance the stiffness of robot joints for optimal force application, allowing for complex 3D operations on non-planar surfaces efficiently.

  • What software tools are used in metal forming?

    Software tools are utilized in metal forming to scan and update models based on formed parts, adjusting for accuracy and quality. They account for factors like sheet deflection and spring back to ensure accurate part formation, enabling robots to perform intricate features on non-planar surfaces seamlessly with tool changers and end effectors.

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Summary

00:00

Exploring Incremental Sheet Forming for Metal Production

  • Destin from Smarter Every Day is exploring incremental sheet forming as part of a manufacturing deep dive series.
  • Incremental sheet forming allows for quick part iteration, beneficial for small-scale production or development.
  • Machina Labs in L.A. is showcasing Roboforming, a method of shaping metal through specialized touch techniques.
  • The process involves using end effectors to deform strong metal sheets, akin to a potter shaping clay.
  • While incremental sheet forming offers unique geometries, it takes longer than traditional stamping methods.
  • The process eliminates the need for costly molds, allowing for faster part production after design completion.
  • Machina Labs utilizes KUKA and Phanax robots for the forming process, with a custom-built control system.
  • The robots apply forces up to 20,000 Newtons, requiring precise calibration to maintain accuracy under load.
  • Continuous feedback and correction mechanisms ensure accurate metal forming despite robot deflection.
  • The complex process involves intricate math and calibration to anticipate and adjust for robot and sheet deflection during forming.

11:15

"Enhancing Robotic Performance Through Actuators and Software"

  • Actuators play a crucial role in transmitting forces down to the base of a robot, with the offset between force and actuator determining torque.
  • Gear trains within actuators can exhibit imperfections like backlash, affecting motion control.
  • Linear actuators, like screw systems, also need to account for backlash when moving back and forth.
  • The rigidity of robot arms impacts their strength and deflection during tasks.
  • Accuracy in robotic movements involves reaching specific points and transitioning accurately between them, considering changing forces.
  • Different poses and optimization strategies can be used to enhance the stiffness of robot joints for optimal force application.
  • Boundary condition effects must be considered in metal deformation calculations to ensure accurate part formation.
  • Software tools are utilized to scan and update models based on formed parts, adjusting for accuracy and quality.
  • Robots can perform complex 3D operations on non-planar surfaces, forming intricate features efficiently.
  • Tool changers and end effectors allow robots to switch between tasks seamlessly, resembling a robotic craftsman.

21:52

Precision Tooling for Titanium Part Formation

  • The bearings lock into the tool through air pressure to prevent it from falling out.
  • Different connections include pneumatic and electrical connections.
  • Tools are primarily made of carbide with a proprietary coating to prevent damage.
  • Software accounts for factors like sheet deflection and spring back to ensure accurate part formation.
  • Robots scan and trim parts accurately before technicians remove them.
  • Working with titanium is challenging due to its toughness, especially in forming.
  • The process involves forming parts with specific angles to ensure rigidity and thickness consistency.
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