Investigation of a combined micro-forming and punching process for the realization of tight geometrical tolerances of conically formed hole patterns

Kolleck, Ralf; Vollmer, Robert; Veit, Robert

doi:10.1016/j.cirp.2011.03.141

Cited by 19 publications

(11 citation statements)

References 9 publications

(3 reference statements)

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“…However, due to the technological constraints of individual manufacturing processes, it is not always feasible to produce components in terms of material, geometry, tolerance and strength etc. [2,3]. Additive manufacturing (AM) techniques, as one of the representatives of the new manufacturing methods, provide the capability with which to produce complex geometries, for example, internal features, which are virtually impossible to create with any other manufacturing process.…”

Section: Introductionmentioning

confidence: 99%

Investigation of part distortions as a result of hybrid manufacturing

Zhu

Dhokia

Nassehi

et al. 2016

Robotics and Computer-Integrated Manufacturing

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a b s t r a c tIn today's society, the customer driven markets has led to the rapid developments and continuous evolution of manufacturing technologies. The ability to accurately produce complex parts, and to reuse and remanufacture used parts is becoming more prevalent, requiring more efficient and rapid methods to be developed. One such method being currently developed is the hybrid process combining additive, subtractive and inspection processes for the manufacture of complex part geometries from any given raw material in terms of shape and size. A major element of the hybrid process is decomposition of a part into a number of subparts, which are additively manufactured and machined in sequence. However, the residual stresses resulting from the temperature difference between the solidified material (i.e. already manufactured subparts) and the material being deposited (i.e. new subparts being built) leads to part distortions, which significantly reduces the dimensional accuracy of finished parts. This study investigates part distortions that take place in the additive manufacturing process under the context of hybrid manufacturing. A method for conducting this investigation was first proposed. A mathematical model was developed, identifying the influential parameters that contribute to part distortions. These parameters were then incorporated in the experimental design by employing the Taguchi design of experiments strategy. Distortion behaviour arising from thermally induced stress was experimentally explored, indicating that part length, height, and layer thickness have significant effects on part distortions.

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Section: Introductionmentioning

confidence: 99%

Investigation of part distortions as a result of hybrid manufacturing

Zhu

Dhokia

Nassehi

et al. 2016

Robotics and Computer-Integrated Manufacturing

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show abstract

“…However, individual manufacturing processes each possess inherent limitations, which cannot be completely eliminated. Due to technological constraints, they are not always feasible for the production of various components in terms of geometries, dimensions and strength etc (Kolleck et al 2011). Computer numerical controlled (CNC) machining of highly complex shapes may be unfeasible owing to limited tool accessibility.…”

Section: Introductionmentioning

confidence: 99%

A novel decision-making logic for hybrid manufacture of prismatic components based on existing parts

2014

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The on-going industrial trend towards high value sustainable manufacturing has led to the emergence of hybrid manufacturing processes. This new generation of processes combines the capabilities of a number of individual manufacturing processes on a single platform. Despite the fact that the drawbacks of individual processes have been significantly reduced, the application of hybrid technology has always been constrained by the capabilities of their constituent processes, in particular the capability to utilise various raw materials in terms of shape and size. This paper introduces a novel concept of hybrid process, which consists of combining additive, subtractive and inspection processes. A feature-based decision-making logic is developed, enabling the hybrid process to reuse existing parts/legacy products. An existing part is first measured for obtaining its geometrical information. Feasible manufacturing strategies are provided and then additive, subtractive and inspection processes are utilised interchangeably to add and/or remove material, transforming the existing part into the final part. This indicates that the iAtractive process is not restricted by raw material geometries. Three identical test parts were manufactured from three existing different shaped parts, demonstrating the efficacy of the proposed hybrid process and the decisionmaking logic in material reuse. New features can be added onto the existing parts and existing features can be removed or further manufactured, giving these parts additional lives, new uses and increased functionality.

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“…Micro-punching first emerged in 2001 with the development of a micro-punching machine by Joo et al, who punched 100 μm holes in 100 μm brass sheets using dies fabricated with micro electrical discharge machining [7]. Subsequent research has almost exclusively been focused on micro-punching various metals 1.5-200 μm thick [7][8][9][10][11][12]. Polymers, however, present a different set of challenges for microscale punching, the topic of the present study.…”

Section: Introductionmentioning

confidence: 99%

Tissue Scaffold Engineering by Micro-Stamping

et al. 2014

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A hand operated benchtop stamping press was developed to conduct research on microscale hole fabrication in polymer membranes for applications as scaffolds in tissue engineering. A biocompatible and biodegradable polymer, poly(ε-caprolactone), was selected for micropunching. Membranes between 30 μm and 50 μm thick were fabricated by hot melt extrusion, but could not be stamped with a 200 μm circular punch at room temperature, regardless of die clearance due to excessive strain to fracture. This problem was overcome by cooling the membrane and die sets with liquid nitrogen to take advantage of induced brittle behavior below the polymer’s glass transition temperature. While cooled, 203 μm hole patterns were successfully punched in 33 μm thick poly(ε-caprolactone) membranes with 11% die clearance, achieving 71% porosity.

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Investigation of a combined micro-forming and punching process for the realization of tight geometrical tolerances of conically formed hole patterns

Cited by 19 publications

References 9 publications

Investigation of part distortions as a result of hybrid manufacturing

Investigation of part distortions as a result of hybrid manufacturing

A novel decision-making logic for hybrid manufacture of prismatic components based on existing parts

Tissue Scaffold Engineering by Micro-Stamping

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