Current Research
Deformation Machining: A New Hybrid Manufacturing Process
Principal investigator:
Graduate student:
Anupam Agrawal
Sponsor:
National Science Foundation
Brief abstract:
The purpose of this proposal is to establish the scientific bases for a new hybrid process, deformation machining, which combines machining of thin structures with single point incremental forming to create unique, complex 3-D components using a three-axis CNC machine. Our research objectives are
- to establish the fidelity of the newly proposed deformation machining process by experimentally investigating the residual stress condition resulting from the process and its effect on fatigue life,
- to create an efficient numerical simulation modeling and simulation method that will significantly reduce the computation time required to analyze new part geometries and process plans, and
- to integrate the experimental and modeling approach with in-process control strategies for process planning, part repeatability and accuracy, and design guidelines.
Impact:
Deformation machining is a unique new manufacturing process that will enable the creation of features that are monolithic, less expensive and more accurate. Previous work in this area has laid the groundwork for achieving these research objectives by demonstrating the concept’s feasibility and creating a wide variety of interesting and useful part features that would be difficult or impossible to create using other processes. Potential applications span a variety of industries including aerospace, automotive, biomedical and electronic components to name a few. We project that for the aerospace industry alone recurring savings could reach $1 billion per year. This value comes from three areas: reduced equipment costs (3-axis machines verses 5 axis), reduced component weight and increased part accuracy. However, even greater benefit in all industries is expected to arise because designers will gain the ability to conceive new structures, which only become economically feasible using the advantages of deformation machining.
Project schedule:
May 2008 to May 2010
Preliminary results:
Using both cutting tools and single point incremental forming tools on the same machine, we have demonstrated that it is possible to make a wide variety of interesting and useful part features that would be difficult or impossible to create using other processes. Preliminary experiments have demonstrated the feasibility of this process on at least two large classes of target parts:
- those where the thin section is not fully constrained around its periphery, resulting in a forming operation that is primarily bending of the wall or floor, and
- those where the thin section is fully constrained, resulting in a forming operation that is primarily stretching of the wall or floor. In addition, we have successfully created unique geometries that demonstrate potential applications in diverse industries including aerospace, biomedical, electronics and others.
Applications for thin floor geometries would include pressurized bulkheads, where the domed feature would allow the floor area to be larger while carrying the same pressure (like the bottom of an aluminum beverage can).
