Deformation Machining

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Student: Dylan Sylvester Advisor: Dr. Bethany Woody

Transcript of Deformation Machining

Page 1: Deformation Machining

Student: Dylan SylvesterAdvisor: Dr. Bethany Woody

Page 2: Deformation Machining

Background

Goals

Project Plan

Current Status

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Background

Goals

Project Plan

Current Status

WhatWhy

How

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Background

Goals

Project Plan

Current Status

Current GoalsBasic Principles

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Background

Goals

Project Plan

Current Status

Timeline

Cost Estimate

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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”

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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

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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

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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

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Modeling of parts to test for stiffness and weight reduction

Simple analysis in SolidWorks COSMOS

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Show that deformation machining can reduce weight while keeping stiffness at a comparable level

Adjust number of domes and dome placement to maximize results

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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

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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

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Optical microscope analysis

What factors affect crack propagation during forming Speed, depth, etc.

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Determine how much cracking will occur at a certain speed or a certain depth

Correlation between floor size and amount of cracking

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* 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

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Certain aspects have already begun F.E. Analysis

Bulkhead research Simple part modeling

Wall Straightness Prepare previous wall samples New sample preparation