Corrugated core panels contain a formed, corrugated core bonded between two skin sheets. These panels are typically used in applications, where a low weight is required with integrity in stiffness. This paper demonstrates the mechanical properties of a simple panel structure (SPS), constructed using strips of work-hardened, austenitic stainless steel (ASS) grade 1.4310 (type 301) with the yield strength (YS) of ~1200 MPa. The 0.5 mm thick strips were formed into a C-shape and subsequently laser welded together by lap joints to form a SPS. The thickness of the SPS was 50 mm. The bending tests for the SPS were carried out transverse and 45-degrees related to the orientation of the web sheet. The results showed that the SPS, as loaded in the transverse direction, has about the same bending stiffness prior yielding as that of the previously tested 6 mm thick, low carbon S355 plain steel sheets, but the SPS is three times lighter than 6mm thick plain steel sheet. Compared with a corrugated core panel made of an annealed ferritic stainless steel (SS-panel) with the YS ~ 250 MPa, the weight of the both panels are roughly the same, but the bending resistance of the SPS is 45% higher. Experimental tests also verified that the benefit in the stiffness is quickly reduced if the load direction differs from transverse. In the 45-degrees loading direction, the SPS and the SS-panel had almost the same bending strength. On the other hand, the SPS and the SS-panel stiffnesses are much better than that of the carbon steel (the YS ~ 300 MPa) panel (CS-panel) in the both loading directions – the SPS being twice as stiff as the CS-panel.
Traditionally forming tools for a press are machined with a CNC-machine. This is quite time consuming - calculating tool tracks, selecting cutting tools, cutting blanks, design fixation and finally machining - especially for a small batch of parts. One alternative method is to cut a die and a draw punch tools from a blank sheet and bunching the plates. Clamping plates together is fast and easy to implement by using for example studs and bars with a certain tolerance to ensure alignment. A laser, a water jet or a plasma cutter can be used for cutting plates. Especially the laser and the water jet cutting are precise methods giving a fine surface quality without a need for fine-tuning. The method saves material compared with machining because a die and a punch could be cut at the same time from a blank sheet as compatible pair as well as the needed amount of plates could be estimated depending of the length of a pressed product. University of Oulu, Oulu Southern institute, Future Manufacturing Technology -group has manufactured several forming tools within this technique and found it extremely suitable for experimenting different solutions and options fast. Furthermore, the method is likely to help especially SMEs in their R&D-phase by lowering production costs in a cost-efficiency way.
This study focused on the systematic error compensation of CNC machines via software way. The method is based on machining test pieces, measuring same for finding the systematic errors of a machine, forming an error map and using the map for correcting the tool paths of the NC-program. Technically, it was shown that by measuring the systematic errors of machines and numerically calculating new, compensated parameters, the precision of aging machines could be substantially improved. Resultingly, the method extends the lifetime of an older machine, postponing the need for new investment for several years.
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