A new methodology of generating optimized tool paths for incremental sheet forming is proposed in this work. The objective is to make parts with improved accuracy. To enable this, a systematic, automated technique of creating intermediate shapes using a morph mapping strategy is developed. This strategy is based on starting with a shape different from the final shape, available as a triangulated STL model, and using step-wise incremental deformation to the original mesh to arrive at the final part shape. Further, optimized tool path generation requires intelligent sequencing of partial tool paths that may be applied specifically to certain features on the part. The sequencing procedure is discussed next and case studies showing the application of the integrated technique are illustrated. The accuracy of the formed parts significantly improves using this integrated technique. The maximum deviations are brought down to less than 1 mm, while average absolute deviations of less than 0.5 mm are recorded.
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