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Currently the main focus in development of forming tools is on improving their galling resistance, mainly by including new forming tool steels, improving surface finish, and applying surface treatments and coatings.
Although the efforts towards improving surface finish have been made over the past decades, the recent developments in science and technology accelerate the progresses made towards superior surface characteristics.
This paper presents an integrated hybrid manufacturing approach to enhance and accelerate the adoption of metal Additive Manufacturing (AM) by adding a direct digital subtractive process to the production that is capable of improving the form, location and position tolerance of critical part features as well as improving surface finish.
This is mainly due to the fact that the newer and more exotic materials such as ceramic and diamond require high speed, rigid industrial machinery to operate correctly and, anyway the benefits of the new materials are more associated with optimising production and extending tool life than with improving surface finish.
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Lubrication improves surface finish in Single Point Incremental Forming (SPIF).
When the built-up-edge becomes unstable and large, it results improved surface finish.
The use of the flat secondary edge was observed to improve surface finish when machining a flat surface.
Hard PVD coating with low thermal conductivity and improved surface finish should be used in this case.
Different types of forming tools and toolpath strategies are explored to improve surface finish and geometrical accuracy by using a customized DSIF machine.
As a result, a higher degree of strain hardening with the ground surface reduced the rubbery or adhesive behavior and improved surface finish after grinding, although a large amount of smearing areas remained.
However, due to the limitation of the achievable surface quality attributed to defects such as burrs and tool marks, a post-polishing process which can maintain the shape of micro features while improve surface finish becomes an indispensable step.
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