Abstract

Monolithic thin-structure parts with intricate geometric designs are employed in a variety of aeronautical, medical, marine, and automotive applications which include the moldlines of the fuselage, turbine blades, impellers, avionic shelves, irregular fins, prostheses, bone and joint support, and skull plates. The deformation machining process is the solution to this challenging and difficult-to-manufacture high-quality components with intricate narrow geometries at competitive prices. The aim of the present study is to assess the effect of process parameters of the deformation machining process wherein a thin, floor-like structure is created by milling and is then formed using a single-point incremental forming tool. Investigation involves the design and development of tooling required for the process followed by feasibility checking of the process. To examine the impact of different process parameters on the process response, the experiments were carried out using the design of experiments. The findings of this study indicate that different process parameters including spindle speed, tool diameter, incremental step depth, and feed rate have a substantial impact on the process response like thickness, surface finish, and hardness. Uneven and non-uniform surface patterns during SEM indicate that it is needed to examine the impact of process parameters. This research involves the feasibility study of a new hybrid technique of deformation machining. Conventionally, a metallic structure is produced by joining various components through welding or by fastening. These methods require additional expenditure on equipment, storage, floor space, human resources, etc. with higher lead time. Joining increases weight and reduces fatigue strength. All these disadvantages can be eliminated by the creation of monolithic structures.