As the application of industrial robots in machining is constantly increasing, many techniques have been developed to make this use more efficient and accurate. The robot controller is one of the key factors to influence the robot performance. This paper discusses the performance of a CNC kernel which is directly integrated into the industrial robot. The dynamic motion of the robot is thoroughly analyzed. A conventional robot controller is carefully evaluated to make a clear comparison.

The formability and geometrical accuracy in incremental sheet forming can be increased using a force-controlled support tool. The main problems in using such a kinematic support tool is the positioning of forming and support tools, while maintaining force magnitude and alignment. A new tool for this was developed systematically using a morphological box. It uses a spring controlled rotation of the tool tip to maintain the force. Since the rotation axis is not in line with the tool tip axis and the tool tip can freely rotate around its axis, roll friction conditions can be achieved. The center of gravity of the rotating part of the tool is placed in the rotating axis and the force is therefore independent from the alignment of the tool in space. It has a mechanical stop with locking option in the vertical position and is therefore also fully usable as a forming tool. While the prototype is manually controlled, concepts for a fully automated version have been designed, as well. First tests are in line with results described in literature, showing that direction and magnitude of force have an influence on the formability. © 2016 Trans Tech Publications, Switzerland.