Capability study of 2D heat-assisted Mill-Bend process
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ORIGINAL PAPER
Capability study of 2D heat‑assisted Mill‑Bend process Ye Li1 · Travis Reents1 Received: 29 June 2020 / Accepted: 23 July 2020 © Springer-Verlag France SAS, part of Springer Nature 2020
Abstract Integrating bending function into multi-axis machine tools will broaden the capability of current manufacturing equipment. However, capability study must be conducted in order to warranty further exploration of such a hybrid manufacturing strategy. This paper presents the capability study of a heat-assisted Mill-Bend process that implements sheet metal bending on a 3-axis milling machine setup. Specifically, the hypothesis is that sheet metal bending can be effectively performed on milling machines, yielding a commensurable accuracy and repeatability as those from traditional bending machines. To this end, two quality characteristics are evaluated—bending angle and bending radius. In the first part of the work, Taguchi parameter design was used to obtain the optimal process parameters. Under the optimal process parameters, the heat-assisted Mill-Bend process is able to produce an improved consistency on bending angle compared to traditional bending process (15.16% and 17.13% reductions of standard deviation in inner angle and outer angle, respectively) although experiencing a slight increase in spring back. In the second part, an elastic–plastic deformation model was used to predict bending radius. The result shows that the predicted radius agrees well with experimental data. In conclusion, heat-assisted Mill-Bend process produces commensurable bending performance when the process is optimized. Keywords Bending · Hybrid manufacturing · Warm forming · Taguchi method · Process optimization
1 Introduction The innovation of manufacturing equipment is driven by an ever-increasing need from manufacturing processes on efficiency, competency and versatility. Although the research effort in the past decades directed towards the fundamental mechanism and physics of manufacturing processes leads to much improved process capability and controllability, the inherent limitations of individual process still constrain each process to be performed on a process-specific machine. The drawbacks resulting from performing manufacturing processes sequentially on a series of process-specific machines have multiple negative impacts to an efficient and effective manufacturing operation. First, each process-specific machine is designed with a dedicated configuration customized to the specific process. As the workpiece goes through the process sequence, the issue of workpiece holding must * Ye Li [email protected] 1
Department of Industrial and Manufacturing Engineering and Technology, Bradley University, 1501 West Bradley Avenue, Peoria, IL 61625, USA
be considered in both product design stage and process planning step. The design model and any intermediate geometry of the workpiece must not interfere with the tool movement in all subsequent processes. This requirement increases the complexity of process planning and imposes a c
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