SGER/GOALI/Collaborative Research: Deformation Machining - A New Hybrid Process

SGER/GOALI/合作研究：变形加工——一种新的混合工艺

• 批准号: 0619996
• 负责人: Jian Cao
• 金额: $ 7.62万
• 依托单位: Northwestern University
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2006
• 资助国家: 美国
• 起止时间: 2006-05-01 至 2008-04-30
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=0619996&HistoricalAwards=false
• 关键词: SGER; GOALI; Collaborative; Research; Deformation

The research objective of this Small Grant for Exploratory Research (SGER)/Grant Opportunity for Academic Liaison with Industry (GOALI)/collaborative research project is to validate the feasibility of a novel hybrid manufacturing process which has the potential to generate complex three-dimensional thinsection parts using a three-axis CNC machine. The new hybrid process, which integrates machining and single point incremental forming into a single CNC machine tool setup, is called Deformation Machining. Combining these processes will enable new part geometries to be created that are not currently possible, and allow some complex parts now requiring a 5-axis machine tool to be fabricated using a 3-axis machine.This new process can enable the flexible and rapid fabrication of lightweight structural components. Potential applications of this process span industries from aerospace to automotive and beyond. Aerospace applications include parts such as bulkheads, frames, spars, stringers, and wingribs. In the aerospace industry alone recurring savings will be substantial. The savings come from three areas: reduced equipment costs, reduced component weight, and increased part accuracy. These savings have been estimated based purely on replication of existing part geometry. However, even greater benefit is expected to arise because designers will gain the ability to conceive new structures which only become feasible using the advantages of deformation machining.

该探索性研究小额资助 (SGER)/学术与工业联络资助机会 (GOALI)/合作研究项目的研究目标是验证新型混合制造工艺的可行性，该工艺有可能使用三轴数控机床生成复杂的三维薄片零件。 这种新的混合工艺将加工和单点渐进成形集成到单个数控机床设置中，称为变形加工。 结合这些工艺将能够创建目前不可能的新零件几何形状，并允许使用 3 轴机床制造一些现在需要 5 轴机床的复杂零件。这种新工艺可以实现轻质结构部件的灵活快速制造。 该工艺的潜在应用涵盖从航空航天到汽车等行业。 航空航天应用包括舱壁、框架、翼梁、纵梁和翼肋等零件。 仅在航空航天业，经常性节省就将是可观的。 节省的成本来自三个方面：降低设备成本、减轻部件重量以及提高部件精度。 这些节省量是完全根据现有零件几何形状的复制来估计的。 然而，预计会产生更大的好处，因为设计人员将获得构思新结构的能力，而这些新结构只有利用变形加工的优势才变得可行。