Fabrication and control architecture of novel hybrid metal additive manufacturing incremental forming technology

建筑 制作 制造工程 控制(管理) 计算机科学 钥匙(锁) 工艺工程 工程类 材料科学 人工智能 历史 医学 操作系统 替代医学 考古 病理
作者
Mithilesh Kumar Tiwari,Shekhar Srivastava,K. Ponappa,Puneet Tandon
标识
DOI:10.1177/14644207241263977
摘要

Hybrid manufacturing processes redefine production dynamics by harnessing the synergistic interplay between process mechanisms, energy sources, and tools to impact manufacturing quality, productivity, and sustainability significantly. Accordingly, this article focuses on hybrid additive manufacturing incremental forming, where additive manufacturing and incremental forming are integrated in a unified setup, driven by a single power source. This integration opens avenues for innovative component and production design, capitalizing on the strengths of both methods while mitigating drawbacks. The fabrication of the hybrid additive manufacturing incremental forming setup involves crucial components like a hybrid extrusion forming unit, supporting plates, hopper-barrel assembly, band heaters, solenoid setup, and a comprehensive control architecture. Addressing challenges, particularly overheating in the hopper, and feeding zone, ensures effective material transformation with the hybrid extrusion forming unit. The subsequent section provides analytical analysis and validation of the hybrid extrusion unit. This technology enhances the entire process and addresses issues related to metal additive manufacturing, such as porosity and material shrinkage. The maximum tensile force sustained in hybrid additive manufacturing incremental forming before fracture demonstrates a notable enhancement of about 20% from 670 N in additive manufacturing to 805 N in hybrid additive manufacturing incremental forming. It also removes micro-cracks, and voids, and improves the inter-layer bonding, as observed through scanning electron microscopy. The results highlight hybrid additive manufacturing incremental forming's superior enhancement of mechanical properties and surface quality compared to traditional additive manufacturing approaches.
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