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.
