Abstract
Robotic roller forming (RRF) is a novel process using an articulated robotic manipulator that can bend Ultra-High Strength materials into thin-walled profiles. For high strength or difficult-to-form sheet materials, a laser can be employed to synchronously heat and soften the local material during RRF. The aim of RRF is to establish itself as a highly flexible process for rapid prototyping as well as for small batch production. However, in finished parts formed with different materials, a new defect that shapes the profile like that of a hook was observed. To overcome this defect and to improve the adaptability of the process, a new analytical model is suggested for the automatic calculation of the tool center point based on the given process parameters. The model was compared to the previous state, where the hook defect was noticeably reduced. Additionally, the control of the bend radius was studied, and the resulting bend radius diverged from the target radius by 0.04 mm (2.45%). Further, when examining the reproducibility, the same bend angles could be achieved as in previous experiments using the constant laser power density. Finally, the development of the bend allowance was studied in various experiments. The analytical model for RRF is a promising method for calculating tool placement and controlling the bend radius in a freeform environment.