Innovative design of a hybrid tool for turning assisted with superficial cold forming

Turning assisted with superficial cold forming (TASCF) is a newly developed manufacturing process directed to simultaneously machine and enhance surface quality/mechanical properties of the components. Although the new hybrid process offers significant manufacturing cost reductions and productivity improvements, still the design of the hybrid tool depends on the application type and has to take into account the technological needs of the 'fused' processes. The paper flags-up some key criteria to be taken into account when employing this novel process, namely: tool design; setup of process parameters. After specifying the technical requirements of TASCF, through iterative 'negotiations' between improved functions and operation constraints of the hybrid process, an optimised tool design of was obtained by 'fusing' turning and superficial cold forming systems. Further design evaluation was also carried which includes TASCF workpiece constraints, control of surface cold forming force as well as geometrical accuracy of machined surfaces. A flowchart methodology to check and design hybrid TASCF tools for other applications has also been presented. Following the described methodology most types of the turning tools can be redesigned for TASCF to enable its implementation within production lines where high precision and surface quality of components are required at enhanced productivity rates.