scholarly journals Deformation at continuous forming of longitudinal welded pipes

2021 ◽  
Vol 64 (1) ◽  
pp. 21-27
Author(s):  
S. V. Samusev ◽  
A. V. Kondrushin ◽  
V. A. Fadeev
Keyword(s):  
Contact Interaction ◽  
Physical Modeling ◽  
Metal Forming ◽  
Deformation Zone ◽  
Horizontal Axis ◽  
Longitudinal Deformation ◽  
Continuous Forming ◽  
Input And Output ◽  
Experimental Values ◽  
Medium Diameter

One of the effective methods for studying any process is its physical modeling, during which it is possible to verify the concepts and hypothesis obtained previously by theoretical modeling. In the laboratory of metal forming of NUST “MISIS” there is ERW mill 30 – 50 for the production and simulation of processes for the continuous forming of longitudinal welded pipes of small and medium diameter, their welding and calibration. This article discusses the deformation zone of a pipe billet, using the first two stands of a molding mill as an example with a calibration of a roll tool for a pipe diam. 50×1.5 mm. Based on the analysis of methods for calculating the parameters of real roll calibers, a model of contact interaction of the pipe billet with the first and second roll open stands was developed and areas of the deformation zone were determined including their sizes: non-intensive and intense impact; input and output contact zones; springing up. Analyzing the conditions of contact interaction of the pipe billet with roll calibers, parameters of the pipe billet in contact with the first-caliber rolls were determined in seven sections, taking into account the features of continuous forming. An analysis of the results has shown that the maximum longitudinal deformation occurred at the edge of the billet in section B – B and was equal to 1.04 %, and for the pipe billet bottom it was 0.92 %. For the experiment, a grid was applied to the pipe billet using a laser engraver. During forming, the trajectory deviation of the pipe billet bottom from horizontal axis was recorded, and sizes of the forming sections were determined. Comparison of theoretical and experimental values has shown that the discrepancy between them does not exceed 7 %.

scholarly journals Realizing a Novel Friction Stir Processing-Enabled FWTPET Process for Strength Enhancement Using Firefly and PSO Methods

Materials ◽  
2020 ◽  
Vol 13 (3) ◽  
pp. 728
Author(s):  
Senthil Kumaran S ◽  
Jayakumar Kaliappan ◽  
Kathiravan Srinivasan ◽  
Yuh-Chung Hu ◽  
Sanjeevikumar Padmanaban ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Process Parameters ◽  
Friction Stir Processing ◽  
Power Plants ◽  
Weld Zone ◽  
Industrial Applications ◽  
Tube Plate ◽  
Friction Stir ◽  
Input And Output ◽  
Experimental Values

The friction welding of tube to tube plate using an external tool (FWTPET) is widely deployed in several industrial applications, such as aerospace, automotive, and power plants. Moreover, for achieving a better tensile strength and hardness in the weld zone, the friction stir processing (FSP) technique was incorporated into the FWTPET process for joining aluminum alloys (AA6063 tube, AA6061 tube plate). Furthermore, it has to be noted that FWTPET was applied for joining the AA6063 tube to the AA6061 tube plate, and FSP was deployed for reinforcing the weld zone with carbon nanotube (CNT) and silicon nitride (Si3N4) particles, thereby attaining the desirable mechanical properties. Subsequently, the Taguchi L25 orthogonal array was used for identifying the most influential input and output FWTPET + FSP process parameters. Furthermore, particle swarm optimization (PSO) and the firefly algorithm (FFA) were deployed for determining the optimized input and output FWTPET + FSP process parameters. The input process parameters include CNT, Si3N4, rotational tool speed, and depth. Furthermore, the tensile strength of the welded joint was considered as the output process parameter. The process parameters predicted by PSO and FFA were compared with the experimental values. It was witnessed that deviation between the predicted and experimental values was minimal. Moreover, it was found that FFA provided a superior tensile strength prediction than PSO.

Simulation of Shock Wave Assisted Free and Shape Forming of Metallic Plates in a Shock Tube

2015 ◽  
Vol 813-814 ◽  
pp. 586-591 ◽  
Author(s):  
Kottakota Kalasagarreddi ◽  
Prem Sai Koppuravuri Sobhan ◽  
Vinay Kumar Gundu ◽  
S.R. Nagaraja
Keyword(s):  
Shock Wave ◽  
Shock Tube ◽  
Metal Forming ◽  
Von Mises Stress ◽  
Stress And Strain ◽  
Shock Strength ◽  
Engineering Problems ◽  
Experimental Values ◽  
Von Mises ◽  
Metallic Plates

Due to their complexity, certain engineering problems like finding shock strength, Mach number etc. and the interaction of shock wave with a structure in free and restricted metal forming techniques cannot be achieved in a single experimentation, these can be obtained only through a number of trials and that leads to increase in cost and time. In such cases both cost and time can be reduced by adopting numerical simulations. In this projectcommercial software ANSYS is used to simulate the propagation shock wave through a shock tube, free and shape forming of metallic plates subjected to this shock wave. Shock Mach numbers up to 2.12 have been generated by varying the driver to driven pressure ratios. Thin copper plates of diameter 60mm and thickness of 0.5mm and 0.3mm are subjected to shock wave loadingin order to form into dies.These dies,madeof structural steel are modelled with pre-defined shapes. The plate peakoverpressures ranging from 9 to 20bar have been generated.The midpoint deflection, Von Mises stress and strain are calculated for free forming copper plates. The simulated results are compared with the experimental values available in literature. The simulated results match well with the experimental values.

Metal Forming With Vibrated Tools

1969 ◽  
Vol 91 (4) ◽  
pp. 1168-1174 ◽  
Author(s):  
Ivan Kristoffy
Keyword(s):  
Metal Forming ◽  
Necessary Conditions ◽  
Force Measurement ◽  
Cold Forging ◽  
Dynamic Force ◽  
Forming Force ◽  
Continuous Forming ◽  
Tool Vibration ◽  
State Of Stress ◽  
Force Reduction

The results of superimposed 20- and 20,000-cps tool vibration in deep drawing, ironing, and cold-forging are presented. Equipment and instrumentation are discussed. The importance of proper dynamic force measurement is emphasized. It was found that: (a) punch vibration resulted in only an apparent force reduction proportional to the workpiece stiffness and vibration amplitude; (b) die vibration caused a true forming force reduction either by changing the direction of friction force or by altering the state of stress; (c) material properties were not affected, although in cold-forging, with superimposed 20,000 cps punch vibration, an apparent force drop of up to 60 percent was achieved; (d) surface finish and deep drawability of the material, under certain conditions, were slightly improved. It is recommended to use superimposed tool vibration only in continuous forming operations, and then only if certain necessary conditions can be satisfied.

scholarly journals Evolution of the Microstructure of the Copper Alloy (DIN-ECu-57) in the Deformation Zone in the Process of Pressing Conform

2018 ◽  
Vol 918 ◽  
pp. 145-151
Author(s):  
Alexander V. Zinoviev ◽  
Alexander N. Koshmin ◽  
Alexander Y. Chasnikov
Keyword(s):  
Mechanical Properties ◽  
Cross Sections ◽  
Metal Forming ◽  
Deformation Zone ◽  
Copper Alloy ◽  
Copper Alloys ◽  
Metal Flow ◽  
Longitudinal Direction ◽  
Microstructure And Mechanical Properties ◽  
Continuous Extrusion

The process of continuous extrusion Conform, relating to modern energy-efficient metalworking technologies, is now widespread in the production of hollow and solid long-cut profiles of various cross-sections made of aluminum and copper alloys. However, in questions relating to the metal flow pattern and the formation of microstructure and mechanical properties, directly at the deformation zone, it has not studied sufficiently [1]. The work aimed at studying the nature of the metal flow and the transformation of the microstructure and mechanical properties of the copper alloy GOST-M1 (DIN-ECu-57) in the deformation zone during the pressing of round (Ø 8, 24, 30 mm) and flat (10 × 30, 10 × 60, 10 × 80, 10 × 100 mm) profiles. It was performed on the basis of New Metallurgical Technologies Ltd. and the department of metal forming of the NUST MISiS. In the pressing process, the templates of these profiles were selected, further samples for experiment were made and the study of the nature of the alloy flow in the longitudinal direction were carried out (continuous casting - deformation center - finished profile).

Extension of the Freiberger Model of Spread for the Calculation of Material Flow during Rolling of Long Products to a New Material Group of Mg Alloys AZ31, AZ81, WE43

2016 ◽  
Vol 716 ◽  
pp. 677-684 ◽  
Author(s):  
Pavel Adamyanets ◽  
Matthias Schmidtchen ◽  
Rudolf Kawalla
Keyword(s):  
Chemical Composition ◽  
Metal Forming ◽  
Material Flow ◽  
Filling Ratio ◽  
Mg Alloys ◽  
Rolling Stock ◽  
Input And Output ◽  
Spread Model ◽  
Numeric Calculation ◽  
New Material

This article shows the extension of an empirical model for the numeric calculation of the spread during rolling Freiberg in calibres developed at TU Bergakademie to Mg alloys AZ31, AZ81 und WE43.The material independent foundations were developed at the Institute of Metal Forming at TU Bergakademie Freiberg.The Freiberger spread model has, through numerous rolling trials and examinations of the material flow, been broadened. Furthermore, the results of the calculations were compared with these trials.The Freiberger model for spread takes the geometrical input and output parameters into consideration, as well as the material flow, the deformation rate v, the deformation temperature θ, the chemical composition of the material Cw, longitudinal tension CL, and friction Cμ between the rolling stock and rolls. And it further considers the diagonal ratio CA∗aKNn of the box pass and the filling ratio of the box pass m.

Novel Five-Axis Forming Press for the Incremental Sheet-Bulk Metal Forming

2013 ◽  
Vol 554-557 ◽  
pp. 1478-1483 ◽  
Author(s):  
Peter Sieczkarek ◽  
Lukas Kwiatkowski ◽  
Nooman Ben Khalifa ◽  
A. Erman Tekkaya
Keyword(s):  
Metal Forming ◽  
Research Centre ◽  
Continuous Forming ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Current State ◽  
Simultaneous Operations ◽  
Flexible Application ◽  
Five Axis ◽  
Functional Components

The incremental procedure of sheet-bulk metal forming was classified into two different forming sequences, the discrete and the continuous. Based on these two groups, a movement matrix was developed, which captures required kinematic motions to manufacture a variety of functional components. With the objective of producing near-net-shape workpiece geometries within the Collaborative Research Centre TR73 – sheet-bulk metal forming, the required positioning accuracies of conventional metal forming machines exceed the current state of the art. Therefore, a suitable machine concept was developed and realized. This new machine represents a unique prototype for a flexible application of bulk forming operations to 2 – 3 mm sheets with five motion axes. During continuous forming, such as rolling, and also during simultaneous operations, increased lateral forces prevail. The machine was provided with a high stiffness. That enables a positioning accuracy which, also under load and at rest, correlates the high demands of the sheet-bulk metal forming within a range of ±0.01 mm.

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