Scribd Logo
Upload

Welcome to Scribd!

  • 66 views

    Bending-Additive-Machining Hybrid Manufacturing of Sheet Metal Structures

    Uploaded by

    Raghavendra Kalyan
    This document describes a hybrid manufacturing methodology that combines bending and additive manufacturing to produce sheet metal structures with additional features. The methodology involves first bending the sheet metal to an intermediate angle for accessibility, then using EDM and TIG deposition to add features before bending to the final angle. Two sample part designs are presented to demonstrate the implementation of this bending-additive process. The methodology allows for increased accessibility during the additive manufacturing steps compared to additive manufacturing alone and provides better control over springback than bending alone.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd

    Bending-Additive-Machining Hybrid Manufacturing of Sheet Metal Structures

    Uploaded by

    Raghavendra Kalyan
    66 views20 pages
    This document describes a hybrid manufacturing methodology that combines bending and additive manufacturing to produce sheet metal structures with additional features. The methodology involves first bending the sheet metal to an intermediate angle for accessibility, then using EDM and TIG deposition to add features before bending to the final angle. Two sample part designs are presented to demonstrate the implementation of this bending-additive process. The methodology allows for increased accessibility during the additive manufacturing steps compared to additive manufacturing alone and provides better control over springback than bending alone.

    Original Description:

    asme msce conference

    Original Title

    MSEC_ppt

    Copyright

    © © All Rights Reserved

    Available Formats

    PPTX, PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    This document describes a hybrid manufacturing methodology that combines bending and additive manufacturing to produce sheet metal structures with additional features. The methodology involves first bending the sheet metal to an intermediate angle for accessibility, then using EDM and TIG deposition to add features before bending to the final angle. Two sample part designs are presented to demonstrate the implementation of this bending-additive process. The methodology allows for increased accessibility during the additive manufacturing steps compared to additive manufacturing alone and provides better control over springback than bending alone.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    66 views20 pages

    Bending-Additive-Machining Hybrid Manufacturing of Sheet Metal Structures

    Uploaded by

    Raghavendra Kalyan
    This document describes a hybrid manufacturing methodology that combines bending and additive manufacturing to produce sheet metal structures with additional features. The methodology involves first bending the sheet metal to an intermediate angle for accessibility, then using EDM and TIG deposition to add features before bending to the final angle. Two sample part designs are presented to demonstrate the implementation of this bending-additive process. The methodology allows for increased accessibility during the additive manufacturing steps compared to additive manufacturing alone and provides better control over springback than bending alone.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 20

    Bending-Additive-Machining

    Hybrid Manufacturing of
    Sheet Metal Structures
    Raghavendra Kalyan Rapthadu
    Faculty Advisor:
    Dr. Ye Li
    Contents
    Introduction
    Objective
    Methodology
    Accessibility Study
    Partition of Deposition Feature
    Spring Back Control
    Overview of Manufacturing Steps
    Fabrication of Design 1
    Fabrication of Design 2
    References
    Conclusion
    Introduction
    Bending is the fundamental process of forming a sheet metal into a certain
    angle and inner radius.
    Additional features on bend parts can serve special purposes.
    The infusion of emerging technologies such as additive manufacturing and
    hybrid manufacturing into traditional bending can help to make additional
    features.

    45o

    135o
    45o
    Objective
    Develop a hybrid manufacturing methodology for making a sheet metal
    bend part with:
    1. additional features
    2. increased accessibility
    3. spring back control

    Table: Comparison of Different Manufacturing Process


    Bending-Additive-
    Property Additive Additive-Machining
    Machining
    Accessibility Medium Medium High
    Material Flow Low Low High
    Cost High Medium Low
    Methodology
    Accessibility study on features

    Feature partition if necessary

    Determine intermediate bend angle

    Calculate minimum enclosing workpiece

    Bend to intermediate angle

    EDM to reduce springback

    Deposition and machining

    Bend to final angle


    Accessibility Study
    Accessibility refers to the reachability of cutters towards workpiece surface
    in CNC machining.

    Accessibility increases with a number of simultaneously controllable axes up


    to 5-axis.
    Particle flow is reachability of metal particle flow towards deposition area in
    additive manufacturing.
    Bending in Steps
    Sheet metal can be bend into an intermediate angle and then bend again to
    its final angle
    The intermediate step helps to overcome the accessibility constraints
    required by CNC machining process at a particular angular range.
    Partition of Deposition Feature
    If the feature to be deposited is inclined to its base then there is a need to
    partition the deposition into two features.
    Partition will serve the following :
    1. separation of the original deposition feature from the base structure
    2. provides a flat surface for perpendicular deposition
    Spring Back Control
    Any sheet metal undergoing forming will tend to get back to its original
    shape upon release of loads resulting in an effect called spring back.
    To eliminate spring back, a thicker workpiece is bend and machined to get
    the intended design with an accurate interior angle.

    Sheet metal springback in bending Design model enclosed in thicker sheet metal

    Traditionally Spring back can be approximately determined by using Gardin


    ers equation
    3
    =1+4 3 Cont.

    Spring Back Control (cont.)
    Above model is resolved using Gardner Equation resulting in these equations:
    Ri Ri
    = sin1 , = sin1 , T1 = L1 2 + R i 2 and
    L1 2 +Ri 2 L2 2 +Ri 2

    T2 = L2 2 + R i 2 , we have T1 sin 1 + T2 sin 2 = 0


    With defined as
    T2 sin + 0 if T1 + T2 cos + 0
    = tan1 + ,
    T1 +T2 cos + if T1 + T2 cos + < 0

    angle 1 can be calculated as 1 = , and 2, t1, t2 and the minimum thickness


    are then solved in turn.
    Overview of Manufacturing Steps
    The sequence of operation are:

    Bending EDM TIG Deposition Machining

    The following intermediate bend angles were achieved after spring back
    control using 0.125 inch workpiece:
    Required Angle Hybrid Machined Part Design Part

    135 Degree 134.9 Degree 137.7 Degree

    150 Degree 149.8 Degree 152.8 Degree


    Process Planning for Design 1 90o

    45o
    45o
    90o
    45o
    135o
    45o
    Coding for Design 1
    Implementation of Design 1
    Process Planning for Design 2
    Coding for Design 2
    Implementation of Design 2
    Conclusion
    A thin-walled workpiece with additional deposition and machining features are
    bent first to obtain its basic structure with deposition and machining operations
    conducted subsequently.
    When accessibility is not available to deposition and machining features, the
    workpiece is bent to an intermediate bending step so that both metal deposition a
    nd removal can be conducted in the process-required orientation.
    Incremental forming to expand the deformation to 3D geometries and explore
    the capability of 5-axis machines to hybrid manufacture more complicated shapes
    will be the future work.
    References
    [1] Tekiner Z., 2004, An experimental study on the examination of springback of sheet metals with several
    thicknesses and properties in bending dies. Journal of Materials Processing Technology, 145(1), pp.109-1
    17.
    [2] Chan W.M., Chew H.I., Lee H.P., Cheok B.T., 2006,"Finite element analysis of Spring-back of V-bendin
    g sheet metal forming processes. J. Mater. Process. Technol. vol.172, pp 3541.
    [3] Li Y. and Sekar A., A Bending-Machining Hybrid Process for Angular Dimensional Accuracy Enhancem
    ent, Proceedings of the 2016 Manufacturing Science and Engineering Conference, MSEC2016, June 27
    -July 1, 2016, Virginia Tech, Blacksburg, USA
    [4] Ren L., Sparks T., Ruan J., and Liou F., 2010, Integrated Process Planning for a Multiaxis Hybrid Manu
    facturing System, Journal of Manufacturing Science and Engineering, APRIL 2010, Vol. 132 / 021006-1
    [5] Karunakaran K. P., Suryakumar S., Pushpa V., and Akula S., 2009, Retrofitment of a CNC machine for
    hybrid layered manufacturing, International Journal of Advanced Manufacturing Technology, 45:690703
    [6] Suryakumar, S., et al., 2011, Weld bead modeling and process optimization in hybrid layered manufact
    uring, Computer-Aided Design, 43 (4), 331344.
    [7] Gardiner F. J., 1957, The Springback of Metals. Trans. ASME, 79, 1, pp. 1-9.
    [8] Black J.T. and Kohser R.A. 2003, Materials and Processes in Manufacturing, Wiley 2012.
    Thank You!

    Any Questions?

    You might also like