2021 Virtual Undergraduate Research Symposium
2021 Virtual Undergraduate Research Symposium
Metamorphic Manufacturing
Metamorphic Manufacturing
PROJECT NUMBER: 67 | AUTHOR: Lauren Drew, Metallurgical and Materials Engineering
MENTOR: Kester Clarke, Metallurgical and Materials Engineering
ABSTRACT
Advanced manufacturing continues to move toward full automation with new developments such as additive manufacturing and CNC machining (subtractive manufacturing) now enabling customized component manufacture with the quality of mass production. The goal of this project is to design robotic controls to automate the blacksmithing process and use deformation processes to enhance the mechanical properties of components without the need for extra machining or tooling. This results in a new “metamorphic” process that combines the customization of blacksmithing with the quality of modern automated manufacturing, creating a flexible process with the advantages of closed die forging. Initially, proper techniques for traditional blacksmithing were learned to identify the variables to control to automate the process. A roto-linear actuator was selected as the initial robot design with two axes of freedom (forward/back and rotational) and used with a hydraulic press to deform annealed 6061 aluminum to different cross-sectional shapes (circle then square, octagon, hexadecagon). The shapes produced by the press and actuator were then compared geometrically to the same shapes produced by hand. It was observed that all shapes produced by the robot had superior geometric symmetry and dimensional accuracy with fewer deformation passes when compared to samples done by hand. Future testing will include die modeling using DEFORM software to control the amount of friction applied and start redundant work experiments.
PRESENTATION
AUTHOR BIOGRAPHY
Lauren Drew is a graduating senior (May 2021) in Metallurgical and Materials Engineering. She has worked with Dr. Clarke with the Center for Advanced Non-Ferrous Structural Alloys (CANFSA) for the last two years working on this project in partnership with a mechanical engineering student, Gabriella Tuell. She has enjoyed working in the forge watching this project go from an idea to an actual robot producing parts better than her own skills! Upon graduation, Lauren will be working for Nucor-Yamato as a plant metallurgist. In the future she is considering returning for graduate school to further her studies in forging and forming.
Hello Lauren, Nice presentation.
If you are interested someday in following up on your idea of inducing redundant work via Equal Channel Angular Pressing or similar methods, I have in my lab multiple Continuous-ECAP machines and also a High Pressure Compressive Shear machine that you are welcome to use.
Meanwhile, best wishes for success at Nucor.
Terry Lowe
Hi Dr. Lowe!
I will pass on that information to Dr. Clarke! If I have time this semester I might ask about it. There are some other undergraduates who will continue working on the project after I graduate so you might hear from the group again next year!
And yes I am excited to work for Nucor. Thank you for checking out my work!
Are there limits on the size or shape of the pieces that can be processed this way?
Hi Colin,
Currently, we are limited to components that start off as a 0.5″ diameter rod, but then through deformation processes, it’s achievable to make almost any shape using just the linear actuator. There are some more complicated shapes that require some additional tooling like fullers that are currently not capable without adding a human component, such as ice axes and any shape that requires punching holes.
What is neat about deforming metals is that you can change out different dies on the press depending on what deformation process you are attempting to do and what you are trying to make. At this point currently though, changing out dies has to be done by a human and is not automated.
I hope that answers your question! Thank you!
Nicely done, Lauren!