Extraction of Coordinate Points

for the Numerical Simulation of Single Point

Incremental Forming Using Microsoft Excel

Zeradam Yeshiwas(&) and Arkanti Krishnaiah

Department of Mechanical Engineering, College of Engineering,

Osmania University, Hyderabad, India
zeruhulu@gmail.com, arakanti@gmail.com

Abstract. The aim of the present paper is to define tool-path in CAM package
and extract the coordinate points from G-code for numerical simulation of
Single Point Incremental Forming (SPIF). The Truncated Cone, Truncated
Pyramid, and Hyperbola were the parts used to define the tool-path in Master-
cam environment. The G-code created from the Truncated Cone and Truncated
Pyramid were the samples in the extraction of X, Y, and Z coordinate points.
Extraction of the coordinate points was conducted by using Microsoft Excel
commands. The paper shows that Excel commands can automatically extract
coordinate points from a huge table of alphanumeric mixed string data. Finally,
the extracted coordinate points were defined for the Numerical Simulation of
SPIF and that works successfully.

Keywords: Incremental forming
Toolpath definition
Extraction
CAM

SPIF

1 Introduction

Single Point Incremental Forming (SPIF) is a dieless sheet metal forming process.
Because of its low initial investment cost, the method is suitable for small batch and
prototyping [1–3].
In the numerical simulation of SPIF, toolpath definition is the primary procedure.
A CAM package with the feature for the tool-path definition of SPIF has not been
introduced. So, CAM systems used in machining have been using as one of the
methods to define the toolpath for the investigations in SPIF.
Efforts were made to extract coordinate points from CAM package for the
Numerical Simulation of SPIF. In simple cases, the tool path point coordinates can be
manually processed by means of simple spreadsheets [4, 5]. Python was used to
generate the ordered file from the part program generated using the CAM package. This
ordered file was given as input to MATLAB to generate position vs time data [3]. The
recent trial was shown by [6], a software tool was used a CNC file in G-code format to
reveal the interpolation point coordinates of the tool motions and the positioning time
in a specific ANSYS format.

© Springer Nature Switzerland AG 2020

S. C. Satapathy et al. (Eds.): ICETE 2019, LAIS 2, pp. 579–588, 2020.
https://doi.org/10.1007/978-3-030-24314-2_69
580 Z. Yeshiwas and A. Krishnaiah

In this paper, a method is introduced to extract the coordinate points from a mixed
string G-code. The approach uses excel commands to extract the coordinate points.

2 Method

The flow chart (Fig. 1) depicted the process that was used to define the tool-path. It also
describes the method used to extract the coordinate points from a mixed alphanumeric
string of G-code.

Import 3D Model (CAD) Create

Toolpath Definition (CAM)

G-Code Generation

YES Extracting Coordinate NO

Points Required?

Extracting Coordinate Introduce to G-

Points Code to CNC Mill

Numerical Simulation Experimental Investigation

Fig. 1. Flow chart for the toolpath definition and extraction of G-code

3 Part Modeling

Three varieties of shapes namely the Truncated Cone, Truncated Pyramid and
Hyperbola have chosen. The dimensions used in the part modeling of the chosen parts
are described in Fig. 2. The wall angle used to define the truncated Pyramid is 60°. To
define the hyperbola the wall angle is varied from 30° to 80°.

4 Toolpath Strategy

Two types of tool-path strategies are commonly used in SPIF. The contour or profile
and the spiral or helical tool-path strategies. In this study the profile tool-path was used.

4.1 Contour Toolpath Definition

Surface Finish Contour tool-paths perform multiple cuts at constant Z step depths. It
has adopted for the multiple forming at constant step depth in SPIF. In this study,
 Extraction of Coordinate Points for the Numerical Simulation 581

Fig. 2. Parameters in the part modeling of sample parts (a) Truncated Cone (b) Truncated
Pyramid (c) Hyperbola

Mastercam version 2017 was the CAM package used. To generate the tool-path a
SolidWorks Part file was imported to Mastercam 2017 version. Then, introducing the
imported file to the surface finish contour was conducted. The parameters used to create
the contour finish tool-path are given in Table 1. Spindle speed is set to be zero because
the tool will not be rotating due to a specific contact area with the sheet. Figure 3
depicted the toolpath created by using Mastercam 2017 version and simulated in
“SIMCO edit” software.

Table 1. Parameters for the toolpath definition in Mastercam

Geometry/parameters Truncated Cone Truncated Pyramid Hyperbola
Tool diameter (mm) U8 U8 U8
Step down (mm) 0.5 0.8 1
Clearance(mm) 0.025 0.025 0.025
Feed rate (mm/min) 1000 1000 1000
582 Z. Yeshiwas and A. Krishnaiah

Fig. 3. Toolpath definition for the sample parts (a) Truncated Cone (b) Truncated Pyramid
(c) Hyperbola

4.1.1 Sample G-Code

The G-code is the main output from the Mastercam environment to drive an automated
CNC Mill and produce the sample parts. The sample G-code created from the 8 mm
diameter tool, 0.5 step depth and 30 mm deep Cone and with the same diameter tool,
depth and with 0.8 mm step depth Pyramid have given in Table 2.

5 Extraction of Coordinate Points

The part program generated using the CAM package cannot be given as input for the
tool path in numerical simulation software. For numerical simulation the tool path
should be defined in terms of position vs time, velocity vs time or acceleration vs
time [3].
In this study, Microsoft Excel approach was used to extract the coordinate points
from a mixed alphanumeric string that make up the G-code. Figure 4 illustrates pro-
cedures in the Excel approach that was used to extract the X, Y and Z coordinate
points.
 Extraction of Coordinate Points for the Numerical Simulation 583

Table 2. Sample G-code for the Truncated Cone and Truncated Pyramid
G-Code for Cone G-code for Pyramid
% %
O0000 (CONE) O0000 (PYRAMID)
N100 G21 N100 G21
N102 G0 G17 G40 G49 G80 G90 N102 G0 G17 G40 G49 G80 G90
N104 T1 M6 N104 T137 M6
N110 Z4.8 N112 G1 Z-.2 F1000.
N112 G1 Z-.2 F1000. N114 X48.768
N114 X-33.113 Y-35.79 N116 Y48.769
N116 X-32.573 Y-36.291 N118 X-48.766
N118 X-30.96 Y-37.682 N120 Y-48.767
N120 X-29.186 Y-39.066 N122 X-47.155 Y-47.156

Import mixed string into Excel

Find the coordinate

Use Excel Command
points of “Z”

Extract coordinate Extract coordinate Repeat Z value until

points of X. points of Y new Z value is seen

Fig. 4. Excel approach to extract coordinate points

The CNC program usually begins with a program number or similar identification,
followed by sequenced blocks of instructions in a logical order. The program ends with
a stop code or a program termination symbol, such as the percent sign [7].
From the G-code sample given in Table 2, CNC programming Preparatory Func-
tions (G codes) and Miscellaneous Functions (M-codes) have found at the beginning
and end of the NC file. Between the two functions, mixed strings of coordinate points
have existed.
The extraction of coordinate points was primarily commenced by removing the
Preparatory Functions, Miscellaneous Functions, and block numbers. To remove block
numbers, use “remove block numbers” option on the NC file itself or introduce the NC
file to “SIMCO edit” software and remove block numbers that way. Table 3 depicts the
sample mixed string after exclusion of the G-codes, M-codes and block numbers from
the NC-file for the Truncated Cone and Pyramid.
After the preparation of the mixed string based on the aforementioned procedure as
depicted in Table 3, the Excel commands given in Table 4 were used to extract the
coordinate points for the Truncated Cone from a mixed alphanumeric string.
584 Z. Yeshiwas and A. Krishnaiah

Table 3. Sample Mixed string for Truncated Cone and Pyramid

Mixed string for Cone Mixed string for Pyramid
Z4.8 Z-.2
Z-.2 X48.768
X-33.113 Y-35.79 Y48.769
X-32.573 Y-36.291 X-48.766
X-30.96 Y-37.682 Y-48.767
X-29.186 Y-39.066 X-47.155 Y-47.156

Table 4. Commands used for the extraction of mixed alphanumeric string

Extraction Command
Left of “Y” Iferror(Left(Text,Search("Y", Text)-1),"")
X-Coordinate points Iferror(Right(Text, Len(Text)- Search("X", Text) - Len("X") + 1),"")
Y-Coordinate Points Iferror(Right(Text, Len(Text)- Search("Y", Text) - Len("Y") + 1),"")
Find Z Iferror(Right(Text, Len(Text)- Search("Z", Text) - Len("Z") + 1),"")
Repeat Z Go To Special” dialog box or VBA code

To repeat “Z” value until a new “Z” value is seen in Excel; firstly select the column
range, Go to Special box, select Blank option, and then OK. After that enter an equal
sign, up arrow, Ctrl + Enter keys simultaneously.
Another optional method can be using VBA code. The following VBA code can
also use to repeat the cell values until a new value is seen [8].
Sub FillDown()
Dim xRng As Range
Dim xRows As Long, xCols As Long
Dim xRow As Integer, xCol As Integer
Set xRng = Selection
xCols = xRng.Columns.CountLarge
xRows = xRng.Rows.CountLarge
For xCol = 1 To xCols
For xRow = 1 To xRows - 1
If xRng.Cells(xRow, xCol) <> "" Then
xRng.Cells(xRow, xCol) = xRng.Cells(xRow,
xCol).Value
If xRng.Cells(xRow + 1, xCol) = "" Then
xRng.Cells(xRow + 1, xCol) =
xRng.Cells(xRow, xCol).Value
End If
End If
Next xRow
Next xCol
End Sub
 Extraction of Coordinate Points for the Numerical Simulation 585

In our case we can use this code to repeat the values of “Z” until new values of “Z”
is seen. To accomplish this, Select the column range, open the Microsoft Visual Basic
for Applications window, Insert, Module. Then copy and paste the below VBA code
into the Module window.

5.1 Sample Toolpath Extraction

In Fig. 5 sample coordinate points for the Truncated Cone depicted in Table 3 were
extracted by using the Excel commands. After extraction, the coordinate points were
introduced to the numerical simulation software to define the toolpath.

Fig. 5. Sample coordinate points extracted (Truncated Cone)

The sample toolpath extracted in Fig. 5 is for a Truncated Cone. The alphanumeric
setup of the mixed string for the Truncated Cone and for the Hyperbola was the same.
However, the alphanumeric setup for Truncated Pyramid was different from the
aforementioned two sample parts. Based on this, the Truncated Cone and Pyramid were
taken to test the extraction.
When it comes to extracting part of a mixed alphanumeric string for Truncated
Pyramid, one of the three Substring functions (Left, Right and Mid) was applied to
quickly handle the first task. After the first extraction by using the Left function, the
same commands in Table 4 were used to extract the coordinate points. In Fig. 6,
sample mixed string coordinate points for Truncated Pyramid depicted in Table 3 were
extracted by using the proposed method.
586 Z. Yeshiwas and A. Krishnaiah

Fig. 6. Extraction of sample coordinate points for Truncated Pyramid

6 Estimated Forming Time

The forming time is the estimated time required to complete the forming process. The
Numerical Simulation in Abaqus required amplitude vs time data to define the toolpath
in SPIF. Estimation of the forming time is possible by relating the feed rate and the
total forming distance or the total distance the tool completed in forming the
part. Equation 2 was used to estimate the forming time.
For face milling and slab milling, the time Tm required to mill a workpiece of
length L is given by Eq. 1.

Tm ¼ L þ A=f r ð1Þ

Where A = approaching distance, mm; L = work length and fr = Feed Rate.

In the current study, the formula can be written as in Eq. 2. The total distance has
found from the SIMCO edit software. After determining the total distance traveled by
the tool, the forming time was computed

Tf ¼ L=f r ð2Þ

Where; Tf = Forming Time; L = Length of Forming and fr = Feed Rate.

The tool-path in the numerical simulation of SPIF in Abaqus should be defined by
using amplitude vs time data. Because of this, it requires the time between each
successive coordinate points. Equation 3 was used to determine the time between each
coordinate point (Fig. 7).

Dt ¼ Tf =N ð3Þ

Where; Δt = Time between each incremental points; Tf = Forming Time and N =

Total number of the coordinate points.
 Extraction of Coordinate Points for the Numerical Simulation 587

Current Coordinate Total distance the

Feed Rate (fr)
points tool covered (L)

Fig. 7. The feed and total distance covered by the forming tool

7 Numerical Simulation

The coordinate points were extracted and used as an input for the numerical simulation
of SPIF and work successfully. In the simulation, the amplitude vs time data extracted
by using the Excel approach is given as input to Abaqus software to simulate the SPIF.
The blank is fixed along its four edges and defined as a deformable body and meshed
with shell elements. The tool is defined as a rigid body. Truncated cone in Fig. 3(a) was
chosen for numerical simulation. The deformed shape after the simulation is shown in
Fig. 8.

Fig. 8. Numerical simulation of the Truncated Cone.

8 Conclusion

Manual extraction coordinate point from a huge table of alphanumeric mixed string
data is tricky. The proposed method can automatically generate the coordinate points
from a huge table of alphanumeric mixed string data for the numerical simulation of
588 Z. Yeshiwas and A. Krishnaiah

SPIF with less effort and time. Besides this, a better agreement can achieve between the
numerical simulation and experimental investigations because of the same coordinate
points.
To use the Excel commands in the extraction of coordinate points there is a need for
exclusion of the G-codes, M-codes and block numbers from the NC-file. In this study,
the commands were not tested for a very complex part.

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