Recent Advances And Research In New Hybrid Technique Deformation Machining

Abstract

Deformation machining is a hybrid process where material is first plastically deformed, and then machining operations (such as milling or turning) are used to refine the shape or surface finish. This hybrid approach leverages the advantages of both plastic deformation—typically seen in processes like forging, bending, or stamping—and precision machining, enabling the production of complex, lightweight, and high-performance parts. This technique is especially useful for industries requiring high precision and strength, such as aerospace, automotive, and medical device manufacturing. Deformation machining combines two emerging manufacturing processes, machining of thin structure and single point incremental forming (SPIF). Single point incremental forming creates sheet metal parts without dies by deformation of local point.  Starting from plate stock, thin features are created by machining operations. Then using forming tool SPIF process is used to create deformations of the thin sections in two different ways, by bending or by stretching. It enables the creation of structure that have geometries that would be difficult or impossible to create by other processes. The parts manufactured are lighter in weight and also less expensive than the replaced parts. Components which were previously made by assembling sheet metal can now be made as monolithic machined component. And this reduces assembling time and precision is also improved. This paper focused on the work that has been carried in the area of deformation machining.