Technical Brief

Investigation of Parametric Effects on Geometrical Inaccuracies in Deformation Machining Process

[+] Author and Article Information
Arshpreet Singh

Department of Mechanical Engineering,
Thapar Institute of Engineering and Technology,
Patiala 147004, Punjab, India
e-mail: arshpreet.singh@thapar.edu

Anupam Agrawal

Department of Mechanical Engineering,
Indian Institute of Technology Ropar,
Room No. 224, Administrative Block,
Rupnagar 140001, Punjab, India
e-mail: anupam@iitrpr.ac.in

1Corresponding author.

Manuscript received May 31, 2017; final manuscript received February 6, 2018; published online May 11, 2018. Assoc. Editor: Radu Pavel.

J. Manuf. Sci. Eng 140(7), 074501 (May 11, 2018) (8 pages) Paper No: MANU-17-1347; doi: 10.1115/1.4039586 History: Received May 31, 2017; Revised February 06, 2018

Deformation machining (DM) is a combination of thin structure machining and single-point incremental forming/bending (SPIF/SPIB). This process enables the creation of complex structures and geometries, which are probably difficult or sometimes impossible to manufacture employing conventional manufacturing techniques. Geometrical discrepancies in thin structure or sheet metal bending and forming are a major obstacle in manufacturing quality components. These discrepancies are more prevalent and complex in nature in incremental or generative manufacturing. In the present work, a comprehensive experimental and numerical study on the parametric effects on various geometrical inaccuracies in DM process has been performed. This study would help in giving an insight in providing necessary geometrical compensation, ensuring a quality product over a wide range of process parameters.

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Fig. 1

Modes of DM: (a) bending mode and (b) stretching mode

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Fig. 2

Fabrication and inspection of DM components: (a) bending mode and (b) stretching mode

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Fig. 8

Effect of process parameters on amount of horizontal inclination at free end: (a) maximum bent angle, (b) wall thickness, and (c) wall height to length ratio

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Fig. 7

(a) Effect of maximum bent angle on error due to curvature and (b) thin structure samples bent at different angles

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Fig. 6

Effect of process parameters on elastic spring back in DM bending mode: (a) maximum bent angle, (b) wall thickness, (c) wall height to length ratio, (d) bending feed rate, (e) incremental angle, and (f) tool diameter

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Fig. 5

Schematic of various geometrical discrepancies in DM bending mode

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Fig. 4

Finite element modeling of DM stretching mode: (a) meshing, (b) boundary conditions and degree-of-freedom, and (c) stretching in dynamic explicit module

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Fig. 3

Finite element modeling of DM bending mode: (a) meshing, (b) boundary conditions and degree-of-freedom, (c) bending in dynamic explicit module, and (d) tool retraction in standard module

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Fig. 9

(a) Schematic showing the bending effect and (b) bending effect in DM stretching mode

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Fig. 10

Effect of process parameters on average radial error in DM stretching mode: (a) tool diameter, (b) forming angle, (c) incremental depth, (d) floor thickness, and (e) floor diameter



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