Experimental force modeling for deformation machining stretching mode for aluminum alloys

Abstract

Deformation machining is a hybrid process that combines two manufacturing processes—thin structure machining and single-point incremental forming. This process enables the creation of complex structures and geometries, which would be rather difficult or sometimes impossible to manufacture. A comprehensive experimental study of forces induced in deformation machining stretching mode has been performed in the present work. A table-type force dynamometer has been used to record the deforming forces in three Cartesian directions. The influence of five process parameters—floor thickness, tool diameter, wall angle, incremental step size, and floor size on the deforming forces—is investigated. Individual as well as combined empirical models of the parameters with regard to the forces have been formed. The results of this study indicate that the average resultant force primarily depends on the floor thickness to be deformed and the incremental depth in the tool path. This could be due to the variation in local stiffness of the sheet with change in floor thickness. The effect of tool diameter, deforming wall angle, and floor size is not significant.