Abstract
Nett-shape manufacturing of components by the plastic deformation of engineering materials is constrained by two factors — the elasticity of tools and that of the machine — the former contributing a lesser order of error in the form of the component than does the latter. The form requirements of some engineering (aerospace) components, which have to be manufactured by the plastic deformation of heat-resistant materials are often beyond that achievable by the current capability of primary processes, the form of these components has to be reduced to the required dimensions by subsequent material-removal operations, which is relatively expensive as the amount of material which has to be removed is small, thus requiring precision fixtures and is difficult to remove at a controlled rate by machining or chemical/discharge processes. The manufacture of such components requires the use of nett-shaping technologies which negate the effects of the elastic behaviour of tools and machinery on component accuracy; the research reported, herein, refers to the technique for negating form-errors which arise from the former. A transducer has been developed to detect all three components of force at selected points on the die-cavity using physical modelling techniques, reiteration of the experiments with different transducer locations enables the development of all three pressure contours on the die-cavity. These contours can, after using the appropriate scaling factors, be used to initialise finite element simulations to determine the elastic characteristics of the die-cavity under forming conditions, from which the die-form compensation requirements can be deduced. This compensated die will enable the nett-shape manufacture of engineering components.
Published Version
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