scholarly journals Sheet Bulk Forming of Thin-Walled Components with External Gearing through Upsetting Using Controllable Deformation Zone Method

2021 ◽  
Vol 34 (1) ◽  
Author(s):  
Xincun Zhuang ◽  
Meile Liang ◽  
Shengfa Zhu ◽  
Yin Zhu ◽  
Zhen Zhao
Keyword(s):  
Material Flow ◽  
Deformation Zone ◽  
Effective Strain ◽  
Sheet Forming ◽  
Forming Process ◽  
Zone Method ◽  
Forming Mechanism ◽  
Bulk Forming ◽  
Thin Walled ◽  
Controllable Deformation

AbstractSheet-bulk metal forming (SBMF) is a promising process for manufacturing complex sheet components with functional elements. In this study, the entire forming process for a typical thin-walled component with external gearing is investigated, including sheet forming and bulk forming processes. Deep drawn cups are prepared during sheet forming; subsequently, upsetting is performed on the sidewall to form external gearing. The upsetting method performed is known as upsetting with a controllable deformation zone (U-CDZ). Compared with the conventional upsetting method, a floating counter punch with a counter force is used in the U-CDZ method such that the forming mechanism is changed into the accumulation of the deformation zone instead of deformation throughout the entire sidewall. The effects of the counter force and material flow are investigated to understand the mechanism. The forming quality, i.e., the formfilling and effective strain distribution, improved, whereas a high forming load is avoided. In addition, a punch with a lock bead is used to prevent folding at the inner corner during the experiment.

scholarly journals Cold Forging Effect on the Microstructure of Motorbike Shock Absorbers Fabricated by Tube Forming in a Closed Die

2021 ◽  
Vol 11 (5) ◽  
pp. 2142
Author(s):  
Trung-Kien Le ◽  
Tuan-Anh Bui
Keyword(s):  
Material Flow ◽  
Cold Forging ◽  
Technological Parameters ◽  
Forming Process ◽  
Tube Forming ◽  
Shock Absorbers ◽  
Thin Walled Tube ◽  
Thin Walled ◽  
Quality Of Products ◽  
Forming Defects

Motorbike shock absorbers made with a closed die employ a tube-forming process that is more sensitive than that of a solid billet, because the tube is usually too thin-walled to conserve material. During tube forming, defects such as folding and cracking occur due to unstable tube forming and abnormal material flow. It is therefore essential to understand the relationship between the appearance of defects and the number of forming steps to optimize technological parameters. Based on both finite element method (FEM) simulations and microstructural observations, we demonstrate the important role of the number and methodology of the forming steps on the material flow, defects, and metal fiber anisotropy of motorbike shock absorbers formed from a thin-walled tube. We find limits of the thickness and height ratios of the tube that must be held in order to avoid defects. Our study provides an important guide to workpiece and processing design that can improve the forming quality of products using tube forming.

scholarly journals A Controlled Material Flow Forming Mechanism of Curve Cutter Forging in The Hot Impression Forging of The Medical Instrument

2021 ◽  
Author(s):  
Yiin-Kuen Fuh ◽  
Chi-Peng Chen ◽  
Wei-Li Wu ◽  
Ming-Shiou Ho ◽  
Ching-Shiang Tzeng
Keyword(s):  
Material Flow ◽  
Medical Instrument ◽  
Medical Surgery ◽  
Manufacturing Cost ◽  
The Novel ◽  
Forming Process ◽  
Flow Forming ◽  
Forming Mechanism ◽  
Improvement Plan ◽  
Critical Technology

Abstract In this study, a forming process during producing medical surgery curve cutter stapler would be tentatively as well as numerically investigated and validated by the simulations. The reasons for the investigation are to find the critical technology of the forming process and to understand this medical tool head forming within the forming process associated with medical surgery curve cutter stapler and improve the traditionally forming process. Moreover, to understand the medical tool head forming, the novel forging process, and the parting line approach are offered and simulated by the FE software QForm, the method data on the medical tool head forging are investigated and compared with the experimental analysis. According to the outcomes of the simulations, the distributions of the forming process, some parameters have been gotten to explain and improve these microscopic phenomena. The precision of the numerical patterns has been confirmed by comparing them with the test dimensions. The offered revised model from the forming preform has been submitted to achieve an alike forging condition when reducing manufacturing cost After the improved method, measure the shrinkage width of the workpiece. Compared with the product of the traditional process, the widest area is 6.37mm shrink to 6.29mm. The shrinkage is about 1%. Compared with the previous result is 5%, the improvement plan has been optimized the outcomes very much.

Bulk-Sheet Forming Process for Products with Thin Wall and Thick Rim

2013 ◽  
Vol 389 ◽  
pp. 273-276
Author(s):  
K.H. Jung ◽  
H.C. Lee ◽  
S. Lee ◽  
E.Z. Kim ◽  
Jung Han Song
Keyword(s):  
Numerical Analysis ◽  
Process Design ◽  
Sheet Forming ◽  
Thin Wall ◽  
Forming Process ◽  
Forging Process ◽  
Backward Extrusion ◽  
One Stage ◽  
Thin Walled

In this study, a novel process to forge thin walled products using bulk-sheet forming concept is developed to overcome drawbacks of a conventional multistage backward extrusion. A newly developed process design is suggested based on numerical analysis, and feasibility of one-stage forging process is discussed.

Through scale material flow investigation in novel incremental bulk forming process

2021 ◽  
Vol 287 ◽  
pp. 116487
Author(s):  
Joanna Szyndler ◽  
Franciszek Grosman ◽  
Marek Tkocz ◽  
Laurent Delannay ◽  
Jiangting Wang ◽  
...  
Keyword(s):  
Material Flow ◽  
Forming Process ◽  
Bulk Forming ◽  
Flow Investigation

Numerical and Experimental Studies of the Precision Forging of a Screw Propeller

2009 ◽  
Vol 419-420 ◽  
pp. 429-432
Author(s):  
Wei Wei Wang ◽  
Fei Han ◽  
Shou Jing Luo
Keyword(s):  
Material Flow ◽  
Flow Line ◽  
Effective Strain ◽  
Experimental Studies ◽  
Forming Process ◽  
Forming Load ◽  
Precision Forging ◽  
Screw Propeller ◽  
Forging Die ◽  
Forging Load

The isothermal precision forging of a screw propeller was studied by means of numerical simulation and experimental forming. The deforming processes of the billet under two different forging patterns were discussed. The distributions of the flow line, the effective strain within the billet and the variation of the forging load during the forming process were analyzed. Results showed that there was a great difference of the effective strain existing between the blades and the wheel hub. The material flow and the distribution of deformation can be improved obviously by adding a core punch on the die. The distribution of deformation and forming load can be changed and controlled by adjusting the process parameters. The forging die was designed and manufactured according to the simulation results and perfect precision forgings have been acquired. Both of the simulation and the forming test showed that the precision forging of screw propellers could be formed with the isothermal precision forging satisfactorily.

scholarly journals Study on Rotary Bending Forming Process of Torsional Damper Shell Pulley

2019 ◽  
Vol 37 (5) ◽  
pp. 1053-1059
Author(s):  
Kemin Xue ◽  
Chao Wu ◽  
Weizheng Yang ◽  
Guangxu Dai ◽  
Ping Li ◽  
...  
Keyword(s):  
Material Flow ◽  
Deformation Zone ◽  
Structural Characteristics ◽  
Metal Flow ◽  
Outer Edge ◽  
Design Criterion ◽  
Structure Design ◽  
Forming Process ◽  
Characteristic Structure ◽  
Rotational Part

To study the integral forming process of torsion damper shell pulley with characteristic structure is of great significance for producing and developing of the rotational part such as shell pulley. A processing way was proposed by combining plate bending forming and roller structure design, to integral forming torsion damper shell pulley. A model for two-step bending forming was establishedvia finite element method. Under the radial feeding of roller, the outer edge of plate was subjected to compress thickening and secondary thickened after bending, and effective stress and metal flow in the deformation zone were analyzed by using marking point. Combining with the structural characteristics of shell pulley, a design criterion "rotating thickening, gathering thickening" of roller was proposed. The metal flow in deformation zone was effectively controlled through the characteristic structure of roller, thereby the specific region to forming multi-wedge toothwas obtained. The quantitative analysis of the instantaneous part section in the forming process, combining with the design criteria of roller structure and material flow rate, radius and arc angle of roller were determined. With the objective forming parameters, the comparison between the simulation results and the experimental are basically coincided, the ribs were fully formed and the specific regions was thickened to minimum value, which verified the feasibility of sheet-bulk metal rotary bending forming theory and the design criterion of roller structure.

Numerical Analysis of Sheet Metal Forming Limit for Local Forming

2014 ◽  
Vol 1028 ◽  
pp. 76-83
Author(s):  
Rui Yang ◽  
Yu Liu ◽  
Peng Fei Wen ◽  
Jun Hua Zhang
Keyword(s):  
Forming Limit Diagram ◽  
Material Model ◽  
Simulation Method ◽  
Sheet Forming ◽  
Forming Limit ◽  
Stress And Strain ◽  
Forming Process ◽  
Geometric Imperfection ◽  
Forming Mechanism ◽  
Geometrical Imperfection

Generally, the forming limit diagram is widely applied to predict the sheet necking and fracture in the conventional sheet forming process. In recent years, the fact that the forming limit is much higher using Incremental sheet forming (ISF) than that obtained in conventional sheet forming, has become a research hotspot in forming mechanism of local forming process. In this paper, the geometrical imperfection in the thickness was presumed to represent local weakening zone and the BAMMAN_DAMAGE material model which using void to describe non homogenization caused by geometric imperfection, were used respectively to investigate the effect of geometry imperfection on the sheet forming limit. Based on the W.C. Emmens’ experiment, the reason and mechanism of enhancement of forming limit during incremental forming was studied through the numerical simulation method. And the variations of stress and strain during the forming process were also studied.

Study of Dieless Radial Spinning for Thick-Walled Cylindrical Parts With External Grooves

2021 ◽  
Author(s):  
Famei Liu ◽  
Junsong Jin ◽  
Wei Rao ◽  
Ying Wang ◽  
Chang Gao ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Material Flow ◽  
Forming Process ◽  
Forming Quality ◽  
Spinning Process ◽  
Cylindrical Parts ◽  
Forming Characteristics ◽  
Thin Walled ◽  
Aluminum Alloy Tube ◽  
Orthogonal Tests

Abstract Thick-walled cylindrical parts with external grooves are common components in the automobile and aviation fields. Such components can be produced by pressing the outer surface of a spinning thick-walled aluminum alloy tube by the dieless radial spinning process. The forming characteristics in the spinning process and the effects of various process parameters on forming were studied by using orthogonal tests and finite element simulations. During the forming process, bulge and thickness reductions occur because of material flow. The results of an investigation of process parameter effects show that the stress yield ratio (ξ) had no significant effect on forming. However, the feed thickness ratio (η) and initial wall thickness of the tube (t0) crucially affected the forming quality (e.g., the heights of bulges and thickness reduction in the groove area). Thick-walled tubes presented different phenomena compared to the thin-walled.

Sign in / Sign up

Export Citation Format

Share Document