Download - Deformation Machining
Student: Dylan SylvesterAdvisor: Dr. Bethany Woody
Background
Goals
Project Plan
Current Status
Background
Goals
Project Plan
Current Status
WhatWhy
How
Background
Goals
Project Plan
Current Status
Current GoalsBasic Principles
Background
Goals
Project Plan
Current Status
Timeline
Cost Estimate
Combination of thin structure machining and single point incremental forming
(SPIF)Thin Structure Machining
S.P.I.F.
Shapes are formed by pushing metal to desired shape
Block of material is machined to thin dimensions, .02” or .04”
1. Machining of a thin wall or floor2. Forming to desired shape with carbide
rod
Both walls and floors are formed using the same tool setup, only the path changes
Machined with 3-axis CNC and relieved end mill
Rolling Direction Aluminum is anisotropic Longitudinal direction is
least desirable direction Forming Speed
Affects final wall shape Affects forming forces Impacts surface cracking
Forming Forces
Safely within machine operating conditions
Reduce assembly cost and time
Reduce weight and keep stiffness high
Create otherwise impossible dimensions
Eliminates need for expensive 5-axis machines and costly training
Extra material in the radius = added weight
Modeling of parts to test for stiffness and weight reduction
Simple analysis in SolidWorks COSMOS
Show that deformation machining can reduce weight while keeping stiffness at a comparable level
Adjust number of domes and dome placement to maximize results
Current forming path leave walls near straight
Improvements to be made to make walls even straighter
Manual CMM to measure points and adjust path accordingly
Y14.5 ansi standard Geometrical Dimensioning and Tolerancing
Create a definition of straightness Form walls and adjust tool paths until
walls are straight as previously defined Multiple materials compliant
Optical microscope analysis
What factors affect crack propagation during forming Speed, depth, etc.
Determine how much cracking will occur at a certain speed or a certain depth
Correlation between floor size and amount of cracking
* Donated from Alcoa**Previously Acquired
Labor hours determined by 15-20 hours a week, for 12 weeks
Description Quantity Price Cost CNC Time 50 $ 16.00 $ 800.00
AlTiN 3 Flute End Mill 4 $ 70.75 $ 283.00 **
4 flute carbide endmill 2 $ 96.35 $ 192.70 **
48x27x5 Al7050-T7451 1 $ 2,000.00 $ 2,000.00 *
Stainless Steel .5"x2"x18" 1 $ 45.00 $ 45.00 Copper .75"x2"x
18" 1 $ 150.00 $ 150.00 Carbide Blank 1 $ 112.55 $ 112.55 **
Labor 192 $ 10.00 $ 1,920.00 Subtotal = $ 5,503.25
Overhead 43% = $ 2,366.40 Total = $ 7,869.65
Certain aspects have already begun F.E. Analysis
Bulkhead research Simple part modeling
Wall Straightness Prepare previous wall samples New sample preparation