International Journal of Machine Tools & Manufacture最新文献

{"title":"Machine tool calibration: Measurement, modeling, and compensation of machine tool errors","authors":"Wei Gao ,&nbsp;Soichi Ibaraki ,&nbsp;M. Alkan Donmez ,&nbsp;Daisuke Kono ,&nbsp;J.R.R. Mayer ,&nbsp;Yuan-Liu Chen ,&nbsp;Károly Szipka ,&nbsp;Andreas Archenti ,&nbsp;Jean-Marc Linares ,&nbsp;Norikazu Suzuki","doi":"10.1016/j.ijmachtools.2023.104017","DOIUrl":"https://doi.org/10.1016/j.ijmachtools.2023.104017","url":null,"abstract":"<div><p>Advanced technologies for the calibration of machine tools are presented. Kinematic errors independently of their causes are classified into errors within one-axis as intra-axis errors, errors between axes as inter-axis errors, and as volumetric errors. As the major technological elements of machine tool calibration, the measurement methods, modeling theories, and compensation strategies of the machine tool errors are addressed. The criteria for selecting a combination of the technological elements for machine tool calibration from the point of view of accuracy, complexity, and cost are provided. Recent applications of artificial intelligence and machine learning in machine tool calibration are introduced. Remarks are also made on future trends in machine tool calibration.</p></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"187 ","pages":"Article 104017"},"PeriodicalIF":14.0,"publicationDate":"2023-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49862596","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Analytical modelling of transient thermal characteristics of precision machine tools and real-time active thermal control method","authors":"Lingtao Weng ,&nbsp;Weiguo Gao ,&nbsp;Dawei Zhang ,&nbsp;Tian Huang ,&nbsp;Guolin Duan ,&nbsp;Teng Liu ,&nbsp;Yingjie Zheng ,&nbsp;Kai Shi","doi":"10.1016/j.ijmachtools.2023.104003","DOIUrl":"https://doi.org/10.1016/j.ijmachtools.2023.104003","url":null,"abstract":"<div><p>Thermal error is one of the primary factors affecting the machining accuracy of precision machining tools. Therefore, it is important to study the transient thermal characteristics of machine tools and the thermal-error control strategies. Thus far, a transient analytical modelling method for characterising the thermal characteristics of machine tools was proposed and an active error control strategy was provided. First, temperature-field modelling was conducted using an analytical method based on the Fourier series method and partial differential equations of heat conduction. Second, using the derived temperature field, the thermal deformation field was calculated based on finite element theory. Subsequently, the continuous real-time effect of the thermal power per unit heat source on the temperature and deformation fields of precision machine tools was studied. The proposed analytical modelling method not only predicts the machine tool heat deformation based on the working conditions of the heat source, but also matches the thermal control source power with the demand of the machine tool heat deformation. The optimal real-time power of the thermal control source is dynamically iterated and matched, such that the thermal deformation caused by the heat and thermal control sources can be balanced in real time at the displacement control point. Finally, the volumetric thermal error was actively controlled by adjusting the temperature field of the machine tool.</p><p>The simulated and experimental results indicate that the transient analytical model can accurately predict the real-time thermal characteristics of the machine tool and that the real-time active thermal control method can effectively reduce volumetric thermal errors. Using active thermal control, the squareness error in the YZ-plane was reduced by approximately 45%, the spindle thermal elongation was reduced from 23 μm to 7 μm, and the volumetric thermal error in the X, Y, and Z directions were reduced by approximately 16, 14, and 17 μm, respectively.</p></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"186 ","pages":"Article 104003"},"PeriodicalIF":14.0,"publicationDate":"2023-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49888082","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Surface formation in laser-assisted grinding high-strength alloys","authors":"Yi He,&nbsp;Guijian Xiao,&nbsp;Shengwang Zhu,&nbsp;Gang Liu,&nbsp;Zhenyang Liu,&nbsp;Zhongcai Deng","doi":"10.1016/j.ijmachtools.2023.104002","DOIUrl":"https://doi.org/10.1016/j.ijmachtools.2023.104002","url":null,"abstract":"<div><p>Laser-assisted machining is a promising method to achieve high efficiency and low damage when machining high-strength alloys. To explore the surface formation in laser-assisted grinding high-strength alloys, laser-assisted scratching was performed on a typical high-strength TC17 titanium alloy material using molecular dynamics simulations and experiments at different laser powers. The scratch force, material removal efficiency based on the scratched surface, and subsurface damage were analysed to determine the laser effects. A smaller scratch force can be achieved by laser assistance, and an appropriate laser power can enhance the material removal efficiency. The molecular dynamics simulation results were consistent with those of the experiments, and the subsurface formation process could be characterised by molecular dynamics simulations. In the laser-assisted scratched subsurface, three layers were found to differ from the matrix: amorphous, ultra-refined, and refined layers. The ultra-refined and refined layers were governed by continuous and discontinuous dynamic recrystallisation mechanisms, respectively, accompanied by different features through transmission electron microscopy analysis. These layers were shallower than those in the conventional scratched subsurface because of the annealing effect and smaller scratch force. In particular, annealing plays an important role in the amorphous layer of the machined surface. Laser-assisted belt grinding experiments were conducted for validation. This study provides significant insights into the low surface damage mechanism of high-strength alloys using laser-assisted machining.</p></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"186 ","pages":"Article 104002"},"PeriodicalIF":14.0,"publicationDate":"2023-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49888081","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Introduction of rolling motion at the tool-tip in metal cutting","authors":"Ashish Kumar ,&nbsp;Abhishek Maurya ,&nbsp;Venu Madhava Kandadi ,&nbsp;Anirban Mahato","doi":"10.1016/j.ijmachtools.2023.104001","DOIUrl":"https://doi.org/10.1016/j.ijmachtools.2023.104001","url":null,"abstract":"<div><p>In metal cutting, severe sliding contact at the tool-chip interface is unavoidable by a conventional cutting tool, which results in sloth motion of chip, higher chip thickness, formation of stagnation zone, higher power consumption, and poor surface finish. To overcome this limitation, rolling motion is introduced at the tool-chip interface by mounting a roller at the tip of a cutting tool – termed as Rotating Tip Cutting Tool (RTC-tool). The roller in RTC-tool rotates during cutting and establishes rolling-sliding contact. A model <em>in-situ</em> experimental configuration is used to study the plane strain flow characteristic of pure copper, notoriously known for higher chip thickness and power consumption, during cutting at low speed. The performance of RTC-tool is compared with sharp cutting-edge and blunt cutting-edge tools (fixed curvature and stationary-roller-tip tool). It is found that rolling motion at the tool-tip decreases the chip thickness and average plastic strain within the chip by about two times than sharp tool and more than two times than the blunt tools. Additionally, there is a significant improvement in surface roughness than the sharp tool. The digital image correlation techniques reveal that flow characteristics within the chip and near the tool-tip interface (retardation region) are influenced by the non-laminar plastic flow of materials. As opposed to the unstable retardation region and periodic cracking at the tool-tip of sharp tool, additional rolling motion at the tool-tip cuts the chip at the incipient stage, forms a stable retardation region, and increases the average velocity of the material in this region. Large retardation region and sloth motion of materials within the retardation region produce large chip thickness during cutting by blunt edge tool. As the chip thickness rather power consumption of the sharp tool is less than the blunt tool, force measurement in nearly orthogonal cutting configuration of RTC-tool compared with the sharp cutting edge. These tests are performed at moderate speed range in a lathe machine. The force measurement data and post-cutting characterization are aligned with the <em>in-situ</em> observations. As the frictional resistance of the roller controls the chip thickness further improvement in the performance of the RTC-tool is possible by reducing the frictional resistance of the roller.</p></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"186 ","pages":"Article 104001"},"PeriodicalIF":14.0,"publicationDate":"2023-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49888083","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Unravelling the ultrasonic effect on residual stress and microstructure in dissimilar ultrasonic-assisted friction stir welding of Al/Mg alloys","authors":"Najib Ahmad Muhammad ,&nbsp;Peihao Geng ,&nbsp;ChuanSong Wu ,&nbsp;Ninshu Ma","doi":"10.1016/j.ijmachtools.2023.104004","DOIUrl":"https://doi.org/10.1016/j.ijmachtools.2023.104004","url":null,"abstract":"<div><p>An in-depth knowledge and understanding of residual stress in dissimilar ultrasonic vibration-assisted friction stir welding (UVaFSW) are crucial for the performance evaluation of multimaterial structure designs; however, extensive research is still lacking. The present study evaluated the residual stress of dissimilar aluminium (Al)/magnesium (Mg) alloy joints produced by traditional FSW and UVaFSW to elucidate the ultrasonic effect mechanism with the aid of process simulation and microstructural evaluation. The weld surficial residual stress measured by X-ray diffraction (XRD) using the cos <em>α</em> method indicated the generation of predominantly compressive stress in UVaFSW welds. In agreement with the XRD measurements, the stress maps evaluated using the contour method (CM) exhibited an expanded compressive stress region and a mitigated tensile stress region in the UVaFSW welds. The Al/Mg interfacial mismatch of thermal expansion led to a tensile stress state on the Mg side and a compressive stress state on the Al side near the Al/Mg interface. The maximum compressive stress in the UVaFSW weld was ∼100 MPa higher than that in the FSW weld. The ultrasonic effect proficiently reduced the layer thicknesses of the intermetallic compounds (IMCs), promoting grain recrystallisation behaviour due to improved material transfer and mixing. Consequently, more homogeneous hardness distributions and improved tensile properties were formed in UVaFSW welds. However, ultrasonic vibration had an insignificant effect on the density of geometrically necessary dislocations and stored strain energy, indicating limited effects on microscopic residual stress in the studied condition. The ultrasonic vibration was found to positively mitigate residual tensile stresses and macroscopic distortion by increasing the temperature and encouraging material mixing within the stirred zone, as well as enhancing the stress interaction of the Al/Mg interface related to thinner IMCs. The UVaFSW has considerable potential to in-process co-optimise residual stress and microstructure for dissimilar Al/Mg welds.</p></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"186 ","pages":"Article 104004"},"PeriodicalIF":14.0,"publicationDate":"2023-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49888084","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Tool-tip dynamics in micromachining with arbitrary tool geometries and the effect of spindle speed","authors":"Shivang Shekhar ,&nbsp;Bekir Bediz ,&nbsp;O. Burak Ozdoganlar","doi":"10.1016/j.ijmachtools.2022.103981","DOIUrl":"https://doi.org/10.1016/j.ijmachtools.2022.103981","url":null,"abstract":"<div><p>Mechanical micromachining has become a leading approach to fabricating complex three-dimensional microscale features and miniature devices on a broad range of materials. To satisfy the accuracy and productivity demands of various micromachining applications, the tool-tip dynamics, i.e., the dynamic behavior of the tool-ultra high-speed spindle assembly as reflected at the cutting edges of a microtool, should be well-understood. However, existing techniques for predicting tool-tip dynamics pose strict limitations in frequency bandwidth and do not capture the effect of the spindle speed on tool-tip dynamics. In addition, those techniques cannot be applied broadly to predict tool tip dynamics for a myriad of microtool geometries. This paper presents a systematic approach to predicting the tool-tip dynamics accurately in micromachining when using ultra-high-speed (UHS) spindles and for arbitrary microtool geometries. The speed-dependent dynamics of the UHS spindle are obtained using an experimental approach. The dynamics of microtools are obtained analytically using the spectral Tchebychev technique, such that any microtool geometry can be modeled accurately and does not require new testing. The tool-tip dynamics are then predicted by combining (coupling) the spindle and microtool dynamics using a novel modal-Tchebychev domain coupling technique. This technique enabled accurate coupling/decoupling of substructure dynamics within a broad frequency bandwidth (up to 15 kHz) and at different spindle speeds (up to 120,000 rpm). Furthermore, an empirical model for the mode-splitting effect is derived to capture the effect of spindle speeds on tool-tip dynamics. The overall approach is demonstrated and experimentally validated on a UHS spindle with microtool blanks and micro endmills at operational speeds. We conclude that the presented methodology can be used to determine the tool-tip dynamics accurately.</p></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"185 ","pages":"Article 103981"},"PeriodicalIF":14.0,"publicationDate":"2023-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49869647","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Novel forming process for aluminum alloy thin shells at ultra-low temperature gradient","authors":"Xiaobo Fan ,&nbsp;Xianshuo Chen ,&nbsp;Shijian Yuan","doi":"10.1016/j.ijmachtools.2022.103992","DOIUrl":"https://doi.org/10.1016/j.ijmachtools.2022.103992","url":null,"abstract":"<div><p>The occurrence of wrinkling and splitting in forming integral aluminum alloy thin shells using traditional forming processes is extremely difficult to preclude. Accordingly, a novel forming process at ultra-low temperature gradient is proposed in this paper. The process leverages the abnormal ‘dual enhancement effect’ of hardening and ductility at ultra-low temperatures. In this proposed approach, the risk unsupported region is fundamentally cooled to ultra-low temperatures to avoid splitting, and the tension-compression stress state is then adjusted by ultra-low-temperature gradient cooling and blank-holder force to control wrinkling. Hyper-hardening and high-ductility properties at ultra-low temperatures are simultaneously utilised to adjust the deformation considering these properties. Mechanical and numerical analyses were conducted to reveal the deformation mechanism, and the effects of ultra-low-temperature gradient, blank-holder force and thickness-to-diameter ratio were studied. The forming defects, thickness, and stress and strain distributions were determined to reflect the deformation behavior. The blank needs to withstand larger deformation to form the thinner components without wrinkling. The maximum radial strain increases by 50% when the thickness-diameter ratio decreases from 13.3% to 3.3‰. A smaller temperature gradient and larger blank-holder force can be used to reduce hoop compressive stress and prevent wrinkling defects. A bigger temperature gradient may be used to increase the stress difference between flange and unsupported regions to further improve forming limit or deformation uniformity, accompanying with easier engineering implementation for large-sized components. An ultra-low temperature forming device was developed to verify the feasibility of this new forming process. The forming limit was significantly improved by cooling the unsupported region, and a more uniform thickness was obtained at a larger ultra-low temperature gradient. The depth of the hemispherical specimen improved by 54.5%, and the average thickness deviation was only 6.9%. Through fundamental research, an integral dome with a diameter of 2.25 m was formed at an ultra-low temperature gradient, surpassing the wrinkling limit and overcoming splitting. The new forming process has considerable potential to fabricate large thin-shell components made of aluminum alloy.</p></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"185 ","pages":"Article 103992"},"PeriodicalIF":14.0,"publicationDate":"2023-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49869648","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Machining of long ceramic fibre reinforced metal matrix composites – How could temperature influence the cutting mechanisms?","authors":"Shusong Zan,&nbsp;Zhirong Liao,&nbsp;Jose A. Robles-Linares,&nbsp;Gonzalo Garcia Luna,&nbsp;Dragos Axinte","doi":"10.1016/j.ijmachtools.2023.103994","DOIUrl":"https://doi.org/10.1016/j.ijmachtools.2023.103994","url":null,"abstract":"<div><p>Metal matrix composites (MMCs) offer a unique set of properties due to the ductile-brittle combination produced by the matrix and the reinforcements. Conventional MMCs are usually particle-reinforced, and their cutting mechanisms have been thoroughly studied, showing that they tend to follow traditional cutting theory as the particles roll within the surface/chip or are pushed in/pulled out of the machined surfaces. However, while the enforcement mechanism is quite unique in fibre reinforced MMCs, very little is known about the cutting mechanisms of this kind of materials. These materials are distinguished for having a, roughly, one-to-one scale alternation of the ductile (i.e., matrix) and hard/brittle (i.e., ceramic fibres) phases; key characteristic that is likely to heavily influence the material removal mechanism. Further, there is an open question on how the (temperature-dependent) stiffness of the matrix would affect the cutting mechanism when considering the hybrid machining process (e.g., heat assisted/cryogenic machining) to improve their machinability. To elucidate these aspects, here, by means of cutting a SiC_f/Ti-6Al-4V MMC, the following particularities/peculiarities of the cutting mechanism of these structures are reported: (1) the chip formation includes, up to now unobserved, extrusion of the ductile component of the MMC (Ti-6Al-4V matrix) between the fractured hard phase (SiC); (2) the properties and deformation mechanisms of the matrix (adjusted by temperature control: −180 °C; 24 °C; 400 °C) will affect the crack initiation of the SiC hard/brittle fibre which is manifested underneath the machined surface. Thus, this work is unique in its approach as it opens the understanding of how these complex and heterogeneous structures could be “activated” (e.g., by thermal means to change the stiffness of a particular phase) for improved cutting conditions.</p></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"185 ","pages":"Article 103994"},"PeriodicalIF":14.0,"publicationDate":"2023-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49869644","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Laser shock peening enables 3D gradient metal structures: A case study on manufacturing self-armored hydrophobic surfaces","authors":"Xiaohan Zhang ,&nbsp;Jian Liu ,&nbsp;Min Xia ,&nbsp;Yaowu Hu","doi":"10.1016/j.ijmachtools.2023.103993","DOIUrl":"https://doi.org/10.1016/j.ijmachtools.2023.103993","url":null,"abstract":"<div><p>Gradient heterostructures typically exhibit excellent mechanical properties. The traditional laser shock method can produce only 1D or 2D gradient structures along the thickness of a material. In this study, we propose a technique called 3D gradient laser shock peening without coating (3LSPwoC) for manufacturing 3D gradient metal structures. An excellent application of this method is the manufacture of multi-scale hydrophobic surfaces with integrated enhanced armor (IE-armor) in a flexible, large-scale and low-cost manner. Hydrophobic surfaces of metals are of great importance, but are typically mechanically fragile and degrade quickly, as the surface nanostructures tend to break under mechanical forces. Current approaches either expose the functional large-aspect-ratio nanostructures directly to external forces or have unbalanced strength-ductility synergy for dynamic loads, resulting in degradation of the properties. A self-armored hydrophobic surface structure was obtained by a combination of laser shock and low surface energy treatment. An IE-armor structure with a well-designed strength-ductility synergy was considered to protect the rich nano-hydrophobic structures. The arrayed micro-pits and abundant micro-nano structures in the pits realized a stable Cassie-Baxter state, resulting in a superhydrophobic surface. The alternating regular distribution of hard and sub-hard domains on the metal surface, together with the soft domain in the core, formed a 3D gradient structure, which achieved excellent synergistic plastic deformation and provided superior mechanical robustness. The 3D gradient metal structure manufactured using the 3LSPwoC process is expected to play a crucial role in highly reliable functional surfaces in aerospace, locomotive manufacturing, and ocean engineering.</p></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"185 ","pages":"Article 103993"},"PeriodicalIF":14.0,"publicationDate":"2023-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49869646","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Deformation mechanisms and fracture in tension under cyclic bending plus compression, single point and double-sided incremental sheet forming processes","authors":"Wenxuan Peng,&nbsp;Hengan Ou","doi":"10.1016/j.ijmachtools.2022.103980","DOIUrl":"https://doi.org/10.1016/j.ijmachtools.2022.103980","url":null,"abstract":"<div><p>This study investigates the deformation and fracture mechanisms of two testing methods, tension under cyclic bending (TCB) and tension under cyclic bending plus compression (TCBC) and their relationship to single point (SPIF) and double-sided (DSIF) incremental sheet forming processes. Experimental tests were carried out by using a bespoke TCBC test rig and a DSIF machine with grade 1 pure Ti samples. The results show the elongation-to-fracture has a high relevance to the bending depth and compression, which leads to detailed investigation to the stress and strain evolutions in the local bending region using finite element (FE) method. A new Gurson-Tvergaard-Needleman (GTN) model is proposed with a modified shear damage mechanism utilising experimental fracture strain loci to calibrate the Lode angle effect under low stress triaxiality. It is found the bending and reverse-bending stages correspond to different stress states and significantly affect the fracture occurrence in TCB, TCBC and SPIF, DSIF processes. For the first time, the stress paths in the plane of stress triaxiality and Lode parameter are used to reveal the transition of deformation modes from equi-biaxial to plane strain tension in SPIF and DSIF, as compared to the plane stress tension in TCB and TCBC. Using the new GTN model, the simulation gives accurate predictions to the elongation-to-fracture in TCB and TCBC, and the fracture depth in SPIF and DSIF with an error of less than 8% in comparison to the experimental results. Although there is a distinction between the equi-biaxial and uniaxial tension deformations, the study concludes that the TCB and TCBC tests provide an insight into the formability improvement and represent intrinsic deformation mechanisms of SPIF and DSIF processes, an ongoing research question, which has drawn considerable attention in recent years.</p></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"184 ","pages":"Article 103980"},"PeriodicalIF":14.0,"publicationDate":"2023-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49900220","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}