Abstract
Hybrid machining-forming technology is a combination of two thin-structural machining and incremental forming manufacturing processes. A group of complex geometry parts in which a thick region is connected to a thin-wall region can be manufactured through this technology with certain advantages. The parts made by this technology require less raw material compared to the ones created by means of machining. The major problem with this technology is the dimensional and geometric inaccuracy of its products which is mainly due to springback. The main purpose of this research was to study the effects of machining parameters and residual stresses induced by the machining primary stage on the subsequent springback after the forming stage. It was found by experiments that the parameters of cutting speed, axial depth of cut, mode of milling, and milling path had a minor effect on springback. However, the workpiece fracture during the forming stage was observed to be sensitive to the prior machining feed rate. Both finite element simulations and experimental results confirmed that the compressive machining residual stresses increased with an increase in the machining feed rate. The compressive residual stresses postponed the onset of fracture at the workpiece lower end during the forming stage. Therefore, we could approach the forming tool closer to the bottom of the wall during forming and, as a result, springback decreased considerably.
Highlights
Parts with thin and integrated walls but complicated geometry are widely applied in different industries such as aerospace, automotive and marine
These results showed that the direction of milling, type of milling, and depth of cut parameters had a minor influence on springback
The effect of the machining process parameters and the residual stresses induced by machining on the subsequent springback after forming in the deformation machining process was studied
Summary
Parts with thin and integrated walls but complicated geometry are widely applied in different industries such as aerospace, automotive and marine. Deformation machining is a process in which two processes, i.e. thin-wall machining and incremental forming, are combined together and performed on a single computer numerical control (CNC) machine. In this process, a raw material block is machined in order to create an integrated thin-wall (vertical or horizontal). A raw material block is machined in order to create an integrated thin-wall (vertical or horizontal) Afterwards, this thin-wall is incrementally formed into the desired shape using a hemi-spherical headed tool. This process offers several advantages compared to the traditional manufacturing processes such machining and forming processes. In spite of its advantages, the dimensional accuracy of the products made by the deformation machining bending mode may not be satisfactory due to springback
Sign-in/Register to view highlights & summary Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a callMore From: The International Journal of Advanced Manufacturing Technology
Disclaimer: All third-party content on this website/platform is and will remain the property of their respective owners and is provided on "as is" basis without any warranties, express or implied. Use of third-party content does not indicate any affiliation, sponsorship with or endorsement by them. Any references to third-party content is to identify the corresponding services and shall be considered fair use under The CopyrightLaw.
