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14. Toolpath Planning for Manufacturing of Complex Parts Through Incremental Sheet Forming

Author

Jiang, Zilin, Liao, Shuheng, Slocum, Alexander H., Leem, Dohyun, Ehmann, Kornel F., Cao, Jian, Jiang, Zilin, Liao, Shuheng, Slocum, Alexander H., Leem, Dohyun, Ehmann, Kornel F., and Cao, Jian

Abstract

Incremental sheet forming (ISF) offers great flexibility in producing complex sheet parts as compared with conventional sheet forming processes where part-specific die sets are required to form a product. While there are many potential applications of ISF in various industries, toolpath planning for multifeature parts remains a leading challenge hindering the wide adoption of ISF. In this study, a criterion based on the gradient of the target surface was established for determining the appropriate feature forming sequence. Based on the analysis of the gradients of the surface, multifeature geometries were separated into two categories: “plane-referenced” and “surface-referenced.” Experimental investigations of forming a multifeature air intake as an example were carried out to demonstrate the proposed criterion and feature forming sequence. The results show that the choice of the optimal sequence depends on the type of geometry formed. The proposed criterion extends existing toolpath strategies for relatively regular geometries, where features are formed from flat or inclined bases to more complex geometries with features on a curved basis. This work will be of interest to both design and manufacturing communities.

Published
2024

38. Introduction

Author

DeVor, Richard E., Ehmann, Kornel F., Ehmann, Kornel F., Bourell, David, Culpepper, Martin L., Hodgson, Thom J., Kurfess, Thomas R., Madou, Marc, Rajurkar, Kamlakar, and Devor, Richard

Published
2007
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40. Cutting forces prediction: The experimental identification of orthogonal cutting coefficients

Author

Popović Mihajlo, Tanović Ljubodrag, and Ehmann Kornel F.

Subjects
cutting forces prediction, cutting coefficients, orthogonal cutting mechanics, tool geometry, Engineering (General). Civil engineering (General), TA1-2040, Mechanics of engineering. Applied mechanics, TA349-359
Abstract

In this paper the cutting coefficients were identified applying the orthogonal cutting mechanics, which are used in the cutting forces and torque prediction. The experiments were performed for material combination of the workpiece (16MnCr5) and tool (HSS-E, EMo5Co5). The first step in the forces prediction acting on a cutting tool is to consider a relatively simple orthogonal cutting process in order to continue to use the results of this analysis as a base for the development of a much more general case of oblique cutting. All cutting operations share the same cutting mechanics principles, but their geometry and kinematics are different. The accepted linear forces model includes both components, due to shearing and ploughing. The total forces are calculated based on the tool geometry by summing all active discretized cutting edges.

Published
2017

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