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Related Concept Videos

Plastic Deformation in Circular Shafts01:20

Plastic Deformation in Circular Shafts

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When materials are subjected to forces that surpass their yield strength, they undergo a process known as plastic deformation. This results in a permanent alteration or strain in their structure. This concept can be specifically applied to circular shafts, where the deformation leads to a change in its shape. The precise evaluation of this plastic deformation requires understanding the stress distribution within the circular shaft, which is achieved by calculating the maximum shearing stress in...
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Transmission Shafts: Problem Solving01:09

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Designing a solid shaft that transmits power from a motor to a machine tool involves a series of calculations to ensure the shaft can withstand the stresses applied by bending moments and torques. First, calculate the torque exerted on the gear, considering the power transmitted by the shaft and its rotational speed. Following this, compute the tangential forces acting on the gears, which directly relate to the torque and the gear radius.
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Design Example: Traverse Angle Computations01:25

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Traverse angle computations are a critical component of surveying, used to compute the internal angles within a closed traverse. A traverse consists of a series of connected lines forming a closed loop, often used for land boundary delineation or mapping. Calculating the internal angles ensures accuracy in the traverse geometry and is essential for checking survey data integrity.The process begins with known azimuths and bearings of the traverse sides. Internal angles at each vertex are...
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Deformation in a Circular Shaft01:10

Deformation in a Circular Shaft

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One of the distinctive characteristics of circular shafts is their ability to maintain their cross-sectional integrity under torsion. In other words, each cross-section continues to exist as a flat, unaltered entity, simply rotating like a solid, rigid slab. To understand the distribution of shearing stress within such a shaft, consider a cylindrical section inside this circular shaft. This section has a length of L and a radius of R, with one end fixed. The radius of the cylindrical section is...
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Design of Transmission Shafts01:16

Design of Transmission Shafts

621
The design of a transmission shaft is governed by two primary specifications: the power it transmits and its rotational speed. These parameters guide the selection of the shaft's material and cross-sectional dimensions, ensuring that the material's maximum shearing stress remains within the elastic limit while transmitting the desired power at the given speed. The system's power is intrinsically linked to the applied torque. The torque applied to the shaft can be calculated by reconfiguring the...
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Thin-Walled Hollow Shafts

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In analyzing a thin-walled hollow shaft subjected to torsional loading, a segment with width dx is isolated for examination. Despite its equilibrium state, this segment faces torsional shearing forces at its ends. These forces are quantitatively described by the product of the longitudinal shearing stress on the segment's minor surface and the area of this surface, leading to the concept of shear flow. This shear flow is consistent throughout the structure, indicating a uniform distribution of...
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Updated: Dec 3, 2025

A Soft Tooling Process Chain for Injection Molding of a 3D Component with Micro Pillars
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Tool Path Design of the Counter Single Point Incremental Forming Process to Decrease Shape Error.

Kyu-Seok Jung1, Jae-Hyeong Yu1, Wan-Jin Chung1

  • 1Department of Mechanical Design and Manufacturing Engineering, Seoul National University of Science and Technology, Seoul 01811, Korea.

Materials (Basel, Switzerland)
|October 27, 2020
PubMed
Summary

A new two-stage incremental forming process, including counter single point incremental forming (counter SPIF), significantly reduces shape errors in sheet metal manufacturing. This method optimizes tool paths for improved accuracy in complex geometries.

Keywords:
compensationcounter formingincremental sheet metal forming processtool path

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Area of Science:

  • Manufacturing Engineering
  • Materials Science
  • Mechanical Engineering

Background:

  • Incremental sheet metal forming offers a flexible alternative to traditional methods, eliminating the need for dedicated tooling.
  • Conventional single point incremental forming (SPIF) processes can suffer from significant shape errors, limiting their applicability.
  • Addressing these errors is crucial for expanding the use of SPIF in producing complex sheet metal parts.

Purpose of the Study:

  • To develop and validate a novel two-stage incremental forming process to mitigate shape errors.
  • To introduce a counter single point incremental forming (counter SPIF) stage for error compensation.
  • To optimize the tool path strategy for both forming stages.

Main Methods:

  • A two-stage process combining initial forming (1st SPIF) and a subsequent counter SPIF stage was designed.
  • The counter SPIF stage applies opposite bending deformation to correct errors like section deflection and spring-back.
  • Tool path optimization for counter SPIF involved modifying previous step tool paths; 1st SPIF tool path was geometry-dependent.

Main Results:

  • Experimental validation using a circular cup shape demonstrated a reduction in shape errors compared to conventional SPIF.
  • The optimized tool path strategy effectively compensated for various geometric inaccuracies.
  • Successful application to a ship-hull geometry confirmed the process's feasibility for complex shapes.

Conclusions:

  • The proposed two-stage incremental forming process, incorporating counter SPIF, is effective in reducing shape errors.
  • The optimized tool path strategy enhances the accuracy and applicability of incremental forming.
  • This method shows significant potential for manufacturing complex sheet metal components with improved fidelity.