Numerical simulation study on multi-pass non-axisymmetric spinning of cylindrical parts with oblique flange

2019 ◽  
Vol 234 (1-2) ◽  
pp. 75-83
Author(s):  
Tao Ye ◽  
Zhen Jia ◽  
Zhi-ren Han ◽  
Bin Xu ◽  
Shude Ji
Keyword(s):  
Wall Thickness ◽  
Thickness Distribution ◽  
Quantitative Relationship ◽  
Cylindrical Part ◽  
Cylinder Wall ◽  
Forming Process ◽  
Design And Optimization ◽  
Spinning Process ◽  
Cylindrical Parts ◽  
Flange Forming

A non-axisymmetric cylinder with an oblique flange has broad application prospects. Spinning is the main production process for this kind of workpiece. Finite element modeling is a necessary method to study some key problems that are difficult to be solved merely through experiments, such as the strain and stress fields in the development of this spinning technology. In this study, the spinning process of a non-axisymmetric oblique flange cylindrical part was established and simulated using ABAQUS/explicit software. The credibility of the simulation result was validated through an experiment. The influence of the axial roller feed along the cylinder wall on the distribution of wall thickness and stress and strain during the forming process was analyzed. The change in stress field and strain field with time was analyzed, and the quantitative relationship between forming conditions and forming results was described. Furthermore, the forming principle of the flange was analyzed. It would be beneficial for flange forming to reduce the increasing distance of the cylinder wall in the 180° direction (parameter c) and the vertical distance from the closest point to the spindle as the roller returns back in the 180° direction (parameter d), to a certain extent. Hence, a workpiece with an ideal appearance was obtained. By comparing the wall thickness distribution, the design and optimization of the roller path were once again verified to be reasonable.

scholarly journals Magnetic Medium-Assisted Inverse Bulge Pre-Forming and Deep Drawing Composite Forming Process for Improving Forming Performance of the Cylindrical Parts

2021 ◽  
Author(s):  
Yuan Yuan Mu ◽  
Feng Li ◽  
Chao Li ◽  
Yun Qi Zang ◽  
Jie Xu
Keyword(s):  
Wall Thickness ◽  
Deep Drawing ◽  
Equivalent Stress ◽  
Stress Gradient ◽  
Cylindrical Part ◽  
Drawing Ratio ◽  
Forming Process ◽  
Cylindrical Parts ◽  
Soft Mold ◽  
Bulge Height

Abstract Due to the poor plasticity of aluminum alloy at room temperature, it is difficult to form thin-walled and complex curved parts. This paper proposes a composite method of inverse bulge pre-forming deep drawing based on intelligent magnetorheological (MR) fluid materials. Through the experiments and finite element modeling of cylindrical parts with drawing ratios of K1=2.125 and K2=2.25 were carried out under different forming conditions. The effect of soft mold medium on the drawing forming of cylindrical parts was studied. The research results show that the uniformity of the wall thickness of the parts is enhanced after using the soft mold medium. When the inverse bulge height is about 9mm and 5mm, the wall thickness variance of the cylindrical part is 0.0023 and 0.0025 pectively, which is reduced by 86.31% and 82.8% respectively. In the pre-forming stage, as the height of inverse bulge is increased, the maximum equivalent stress moves from the fillet area of the blank holder to the outer surface of the highest point of the bulging area. Taking drawing ratio of K1=2.125 as an example, the circumferential compressive stress in the flange area decreases and is distributed unifomly under the back pressure and soft drawbeads, the radial stress gradient and equivalent stress gradient at the fillet of die are reduced; For cylindrical parts with drawing ratios of K1=2.125 and K2=2.25, when the inverse bulge height is 9mm and 5mm, the forming effect of the part is the best.

scholarly journals Optimization of Superplastic Forming Process of AA7075 Alloy for the Best Wall Thickness Distribution

2021 ◽  
Vol 6 (4) ◽  
pp. 251-261
Author(s):  
Manh Tien Nguyen ◽  
Truong An Nguyen ◽  
Duc Hoan Tran ◽  
Van Thao Le
Keyword(s):  
Wall Thickness ◽  
Deformation Temperature ◽  
Numerical Optimization ◽  
Thickness Distribution ◽  
Superplastic Forming ◽  
Forming Process ◽  
Wall Thickness Distribution ◽  
Surface Method ◽  
Series Of Experiments ◽  
The Relationship

This work aims to optimize the process parameters for improving the wall thickness distribution of the sheet superplastic forming process of AA7075 alloy. The considered factors include forming pressure p (MPa), deformation temperature T (°C), and forming time t (minutes), while the responses are the thinning degree of the wall thickness ε (%) and the relative height of the product h*. First, a series of experiments are conducted in conjunction with response surface method (RSM) to render the relationship between inputs and outputs. Subsequently, an analysis of variance (ANOVA) is conducted to verify the response significance and parameter effects. Finally, a numerical optimization algorithm is used to determine the best forming conditions. The results indicate that the thinning degree of 13.121% is achieved at the forming pressure of 0.7 MPa, the deformation temperature of 500°C, and the forming time of 31 minutes.

scholarly journals Hot Gas Forming of Aluminum Alloy Tubes Using Flame Heating

2020 ◽  
Vol 4 (2) ◽  
pp. 56 ◽  
Author(s):  
Ali Talebi-Anaraki ◽  
Mehdi Chougan ◽  
Mohsen Loh-Mousavi ◽  
Tomoyoshi Maeno
Keyword(s):  
Aluminum Alloy ◽  
Wall Thickness ◽  
Thickness Distribution ◽  
Forming Process ◽  
Hot Gas ◽  
Axial Feeding ◽  
Flame Heating ◽  
Lathe Machine ◽  
Aluminum Alloy Tube ◽  
Hot Gas Forming

Hot metal gas forming (HMGF) is a desirable way for the automotive industry to produce complex metallic parts with poor formability, such as aluminum alloys. A simple hot gas forming method was developed to form aluminum alloy tubes using flame heating. An aluminum alloy tube was heated by a flame torch while the tube was rotated and compressed using a lathe machine and simultaneously pressurized with a constant air pressure. The effects of the internal pressure and axial feeding on expansion and wall thickness distribution were examined. The results showed that the proposed gas forming method was effective for forming aluminum alloy tubes. It was also indicated that axial feeding is a vital parameter to prevent reductions in wall thickness by supplying the material flow during the forming process.

The Influence of the Roller Forming Path on the Neck-Spinning Process of Tube at Elevated Temperature

2011 ◽  
Author(s):  
Chi-Chen Huang ◽  
Jung-Chung Hung ◽  
Cheng-Chan Lo ◽  
Chia-Rung Lin ◽  
Chinghua Hung
Keyword(s):  
Finite Element ◽  
Elevated Temperature ◽  
Elevated Temperatures ◽  
Thickness Distribution ◽  
Optimization Technique ◽  
Element Model ◽  
Strain Rates ◽  
Forming Process ◽  
Tube Spinning ◽  
Spinning Process

The tube spinning process is a metal forming process used in the manufacture of axisymmetric products, and has been widely used in various applications. In this paper, the neck-spinning process was applied to form the neck part of the tube end at an elevated temperature. The spun tube was used as a high pressure CO2 vessel, which is a component of motorcycle airbag jackets. An uneven surface will occur on the tube surface if the thickness distribution of the tube is not uniform after the neck-spinning process. This is because different thicknesses result from different contractions during the cooling stage. For this reason, the aim of this research was to numerically investigate the roller forming path to improve the thickness distribution of the tube during the neck-spinning process. The finite element method was used to simulate the neck-spinning process of the tube at an elevated temperature. For the construction of the material model, special uni-axial tensile tests were conducted at elevated temperatures and various strain rates, because the material is sensitive to strain rates at high temperatures. This paper compares the experimental and simulation results of the thickness distribution and the outer contour of the spun tube. The validated finite element model was used to investigate the influence of the roller forming path on the thickness distribution of the tube. The thickness distribution of the tube formed by a curved path was found to be more uniform than for the tube formed by a straight path. Finally, the optimization technique was used to find the optimal forming path, and the optimal result was verified experimentally.

Three Dimensional Finite Element Analysis on Neck-Spinning Process of Thick-Walled Tube at an Elevated Temperature

2012 ◽  
Vol 579 ◽  
pp. 269-277 ◽  
Author(s):  
Chi Chen Huang ◽  
Hsin Yen Fan ◽  
Ching Hua Hung ◽  
Jung Chung Hung ◽  
Chia Rung Lin
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Elevated Temperature ◽  
Thickness Distribution ◽  
Forming Process ◽  
Outer Contour ◽  
Tube Spinning ◽  
Element Analysis ◽  
Spinning Process ◽  
Simulation Results

Tube spinning is a metal forming process used to manufacture axisymmetric products. This study chose a seamless thick-walled steel tube to manufacture a high pressure vessel. Finite element analysis was successfully applied to the neck-spinning process of a thin-walled tube; however, previous research has not investigated the neck-spinning process of thick-walled tubes. Therefore, the aim of this research was to investigate numerically the neck-spinning process of thick-walled tubes at an elevated temperature. The commercial software Abaqus/Explicit was adopted in the simulation. This paper compares experimental and simulation results on thickness distribution and outer contour of the spun tube. During the final stage, the average deviations between the simulation and experiment were 6.74% in thickness and 4.97% in outer contour. The simulation results correspond with those derived in the experiment.

Process Parameter Optimization for Better Hydro-Forming Performance of a Trailing Arm Tube

2013 ◽  
Vol 465-466 ◽  
pp. 704-708
Author(s):  
Shen Yung Lin ◽  
Hong Yi Liao
Keyword(s):  
Process Parameters ◽  
Wall Thickness ◽  
Tube Wall ◽  
Thickness Distribution ◽  
Equivalent Stress ◽  
Process Parameter ◽  
Hydraulic Pressure ◽  
Forming Process ◽  
Tube Wall Thickness ◽  
Forming Characteristics

This work presents the tube forming characteristics of a trailing arm which the whole forming processes are arranged through pre-bending twice and hydro-forming once. This work utilizes the finite element method to simulate the hydro-forming process of the trailing arm by changing the process parameters, such as velocity of left and right punches and internal hydraulic pressure, etc. The effects of process parameters on the distribution states of the tube wall-thickness, distribution of equivalent stresses and strains, and formability of the forming arm are thus investigated. Taguchi method, orthogonal array and factor response are then applied together to determine the optimal process parameter combinations corresponding to two single-quality objects, minimum tube wall-thickness and maximum equivalent stress, with nominal-the-best and smaller-the-better, respectively. It shows that the velocity of the right punch for the billet material axial feeding supplement should be larger than that of the left punch preventing the uneven bursting of the tube-wall on right-end. The analysis of variance also shows that left punch velocity is a major contribution parameter for tube wall-thickness while that primarily affects the equivalent stress is the internal pressure.

Thickness of Magnesium Alloy Cylindrical Cup in Pressure-Lubricating Deep Drawing

2012 ◽  
Vol 189 ◽  
pp. 147-151
Author(s):  
Xian Chang Mao ◽  
Hai Yan Lin
Keyword(s):  
Magnesium Alloy ◽  
Wall Thickness ◽  
Deep Drawing ◽  
Thickness Distribution ◽  
Blank Holder Force ◽  
Technological Parameters ◽  
Forming Process ◽  
Blank Holder ◽  
Deformation Behaviors ◽  
Cylindrical Cup

Forming process of AZ31B magnesium alloy cup parts in pressure-lubricating deep drawing was simulated by Dynaform at room temperature. The technological parameters which influence the wall thickness difference of cup parts were investigated in this paper, including internal pressure, blank holder force and punch corner radius, etc. Compared with the deformation behaviors of magnesium alloy in mechanical deep drawing and pressure-lubricating deep drawing, the wall thickness distribution of cup parts was discussed. The result shows that preferable deformation behaviors can be obtained in pressure-lubricating deep drawing when adopted adaptive technological parameters.

scholarly journals Manufacture of Defined Residual Stress Distributions in the Friction-Spinning Process: Investigations and Run-to-Run Predictive Control

Metals ◽  
2022 ◽  
Vol 12 (1) ◽  
pp. 158
Author(s):  
Frederik Dahms ◽  
Werner Homberg
Keyword(s):  
Residual Stress ◽  
Predictive Control ◽  
Stress Generation ◽  
Hole Drilling ◽  
Stress Distributions ◽  
Forming Process ◽  
Hole Drilling Method ◽  
Drilling Method ◽  
Spinning Process ◽  
Flange Forming

Friction-spinning as an innovative incremental forming process enables high degrees of deformation in the field of tube and sheet metal forming due to self-induced heat generation in the forming area. The complex thermomechanical conditions generate non-uniform residual stress distributions. In order to specifically adjust these residual stress distributions, the influence of different process parameters on residual stress distributions in flanges formed by the friction-spinning of tubes is investigated using the design of experiments (DoE) method. The feed rate with an effect of −156 MPa/mm is the dominating control parameter for residual stress depth distribution in steel flange forming, whereas the rotation speed of the workpiece with an effect of 18 MPa/mm dominates the gradient of residual stress generation in the aluminium flange-forming process. A run-to-run predictive control system for the specific adjustment of residual stress distributions is proposed and validated. The predictive model provides an initial solution in the form of a parameter set, and the controlled feedback iteratively approaches the target value with new parameter sets recalculated on the basis of the deviation of the previous run. Residual stress measurements are carried out using the hole-drilling method and X-ray diffraction by the cosα-method.

Research on Variation of Stress and Strain Field and Wall Thickness during Cone Spinning

2006 ◽  
Vol 532-533 ◽  
pp. 149-152 ◽  
Author(s):  
Mei Zhan ◽  
He Yang ◽  
Jin Hui Zhang ◽  
Yin Li Xu ◽  
Fei Ma
Keyword(s):  
Wall Thickness ◽  
Large Strain ◽  
Metal Flow ◽  
Small Region ◽  
Small Ring ◽  
Forming Process ◽  
Optimization Of Process Parameters ◽  
Spinning Process ◽  
Metal Forming Process ◽  
In The Beginning

Cone spinning is an advanced but complex metal forming process under coupled effects of multi-factors. Understanding the deformation mechanism, i.e., the stresses, strains, and metal flow in the deformation zone during the process is of great significance for optimizing the spinning process and controlling the product quality. In this paper, based on ABAQUS/Explicit, a reasonable FEM model for cone spinning with a single roller has been established, and the features of stress, strain and wall thickness during the process have been obtained. The results show the following: (1) In the beginning, large stress, large strain and the acute thinning of wall thickness localize at the small region below the roller, then the region extends into a small ring, further it becomes a large ring, and finally the ring will become uneven if the wrinkling occurs in the flange. (2) After spinning, the acute thinning region locates at the midst of the wall near the bottom of the workpiece. (3) At earlier stage of cone spinning, as a result of the acute thinning of wall thickness in the wall zone, the unevenness of wall thickness increases sharply to a value, then it almost keeps the value at the stable stage, and finally it will slowly increase again if the wrinkling appears in the flange. The results are helpful for determination and optimization of process parameters of cone spinning.

Thickness and Microstructure Analysis on Hot Gas Bulged Cup-Shaped Parts of Ti-22Al-24.5Nb-0.5Mo

2016 ◽  
Vol 716 ◽  
pp. 138-143
Author(s):  
Yong Wu ◽  
Gang Liu ◽  
Zhi Qiang Liu ◽  
Bei Bei Kong
Keyword(s):  
Mechanical Properties ◽  
Cylindrical Part ◽  
Outer Diameter ◽  
Jet Engines ◽  
Forming Process ◽  
Complex Phase ◽  
Hot Gas ◽  
Cylindrical Parts ◽  
Application Potential ◽  
Hot Gas Forming

Ti2AlNb based alloy has been paid more and more attention in recent years because of their high application potential in jet engines for good mechanical properties at high temperature. However, the control of microstructure and mechanical properties for components in sheet metal forming is very difficult because the complex phase transformation. In this paper, a cylindrical part was produced by hot gas forming and the formability of a Ti-22Al-24.5Nb-0.5Mo sheet with thickness of 2mm was studied at 985°C. It is found that the parts could be formed with small bottom-corner radius of 4mm with outer diameter of 60mm and the depth of 20mm. The strain distribution and thinning ratio of the parts were analyzed. The maximum thinning ratio was 56.3% near to the small corner. The microstructures of the original blank and the cylindrical parts were observed by optical microscopic (OM). It is found that the orthorhombic (O) phase and α2 phase significantly reduced during the forming process. On the other hand, at different position of the parts, different microstructures appear because of different strain values.

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