Abstract:
Deformation machining (DM) is a combination of thin structure machining and single point incremental
forming/bending. This process enables creation of monolithic structures with complex geometries
employing conventional tooling and equipment. In the present work, a comprehensive experimental
and numerical (finite element) investigations on structural thinning, evolution of thinning across the
forming depth in DM stretching mode has been performed. Structural thickness was found to be highly
non uniform along the forming depth across all the investigated fixed and variable forming angles pro-
files. Structural thickness of the formed structure influences the strength and stiffness of the formed
component. A theory behind non-uniform and reducing thickness profile has been proposed from the
analysis of thinning evolution of the same formed profile at varied forming depths. Finally, a compensation
strategy in thin structure machining has been proposed to obtain uniform structural thickness
encompassing variable profiles in incremental forming. In this strategy, a relationship to machine an
initial non-uniform section thickness radially taking the uncompensated formed thickness profile into
consideration is obtained in order to achieve a uniform formed thickness profile.
