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.

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 Comparison of Computer Extended Descriptive Geometry (CeDG) with CAD in the Modeling of Sheet Metal Patterns

Symmetry ◽  
2021 ◽  
Vol 13 (4) ◽  
pp. 685
Author(s):  
Manuel Prado-Velasco ◽  
Rafael Ortiz-Marín
Keyword(s):  
Sheet Metal ◽  
Computer Aided Design ◽  
Parametric Modeling ◽  
Descriptive Geometry ◽  
The Novel ◽  
Forming Process ◽  
Solid Models ◽  
Design Software ◽  
Solid Edge ◽  
Aided Design

The emergence of computer-aided design (CAD) has propelled the evolution of the sheet metal engineering field. Sheet metal design software tools include parameters associated to the part’s forming process during the pattern drawing calculation. Current methods avoid the calculation of a first pattern drawing of the flattened part’s neutral surface, independent of the forming process, leading to several methodological limitations. The study evaluates the reliability of the Computer Extended Descriptive Geometry (CeDG) approach to surpass those limitations. Three study cases that cover a significative range of sheet metal systems are defined and the associated solid models and patterns’ drawings are computed through Geogebra-based CeDG and two selected CAD tools (Solid Edge 2020, LogiTRACE v14), with the aim of comparing their reliability and accuracy. Our results pointed to several methodological lacks in LogiTRACE and Solid Edge that prevented to solve properly several study cases. In opposition, the novel CeDG approach for the computer parametric modeling of 3D geometric systems overcame those limitations so that all models could be built and flattened with accuracy and without methodological limitations. As additional conclusion, the success of CeDG suggests the necessity to recover the relevance of descriptive geometry as a key core in graphic engineering.

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 Flexible Die Design and Springback Compensation Based on Modified Displacement Adjustment Method

2014 ◽  
Vol 6 ◽  
pp. 131253 ◽  
Author(s):  
Young-Ho Seo ◽  
Ji-Woo Park ◽  
Woo-Jin Song ◽  
Beom-Soo Kang ◽  
Jeong Kim
Keyword(s):  
Closed Loop ◽  
Three Dimensional ◽  
Loop System ◽  
Die Design ◽  
Manufacturing Cost ◽  
Closed Loop System ◽  
Forming Process ◽  
Element Analysis ◽  
Springback Compensation ◽  
Flexible Die

Springback in metal forming process often results in undesirable shape changes in formed parts and leads to deterioration in product quality. Even though springback can be predicted and compensated for through the theories or methodologies established thus far, an increase in manufacturing cost accompanied by a change in die shape is inevitable. In the present paper, it is suggested that the cost accompanied with springback compensation can be minimized while allowing the processing of various three-dimensional curved surfaces by using a flexible die composed of multiple punches. With the die being very flexible, the iterative trial-and-error method can be readily applied to compensate for the springback. Thus, repeated designing and redesigning of solid or matched dies can be avoided, effectively saving considerable time. Only some adjustments of punch height are required. Detailed designs of the flexible die as well as two core algorithms to control the respective punch heights are described in this paper. In addition, a closed-loop system for the springback compensation using the flexible die is proposed. The amount of springback was simulated by a finite element analysis and the modified displacement adjustment (DA) method as the springback compensation model was used in the closed-loop system. This system was applied to a two-dimensional quadratic shape problem, and its robustness was verified by an experiment.

The Strain Analysis at the Broadening Stage of the Hollow Railway Axle by Multi-Wedge Cross Wedge Rolling

2014 ◽  
Vol 494-495 ◽  
pp. 457-460 ◽  
Author(s):  
Bin Hu ◽  
Xue Dao Shu ◽  
Peng Hui Yu ◽  
Wen Fei Peng
Keyword(s):  
Production Efficiency ◽  
Strain Analysis ◽  
Cross Wedge Rolling ◽  
Forming Process ◽  
Element Analysis ◽  
Forming Mechanism ◽  
Railway Axle ◽  
The Finite Element Analysis ◽  
Scientific Significance ◽  
Deform 3D

The paper is based on the newest hollow railway axle, which utilizes the Pro/E designed multi-wedge cross wedge rolling (MCWR) model, utilizes the finite element analysis software DEFORM-3D to complete the numerical simulation about the whole stage of the hollow railway axle forming process, and analyzes the strain rule at the broadening stage of the hollow railway axle, especially conducts a detailed research on forming character into the strain rule at the multi-wedge transition stage, and finally gets the strain forming mechanism of the hollow railway axle at the broadening stage. The result of the research on the strain rule poses great scientific significance on enhancing the product quality and the production efficiency of the hollow railway axle, and improving the theory of multi-wedge cross wedge rolling.

Numerical Study of the Flow Forming Process of AISI 630 Stainless Steel

2011 ◽  
Vol 264-265 ◽  
pp. 24-29 ◽  
Author(s):  
Seyed Mohammad Ebrahimi ◽  
Seyed Ali Asghar Akbari Mousavi ◽  
Mostafa Soltan Bayazidi ◽  
Mohammad Mastoori
Keyword(s):  
Feeding Rate ◽  
Surface Defects ◽  
Numerical Study ◽  
Internal Diameter ◽  
The Finite Element Method ◽  
Forming Process ◽  
Flow Forming ◽  
Cold Forming ◽  
External Variables ◽  
Experimental Process

Flow forming is one of the cold forming process which is used for hollow symmetrical shapes. In this paper, the forward flow forming process is simulated using the finite element method and its results are compared with the experimental process. The variation of thickness of the sample is examined by the ultrasonic tests for the five locations of the tubes. To simulate the process, the ABAQUS explicit is used. The effects of flow forming variables such as the angle of rollers and rate of feeding of rollers, on the external variables such as internal diameter, thickness of tube and roller forces are considered. The study showed that the roller force and surface defects were reduced with low feeding rate and low rollers attack angles. Moreover, the sample internal diameter increased at low feeding rate and low rollers attack angles. The optimum variables for flow forming process were also obtained.

scholarly journals Material flow control in sheet-bulk metal forming processes using blasted tool surfaces

2018 ◽  
Vol 190 ◽  
pp. 13003 ◽  
Author(s):  
Marion Merklein ◽  
Maria Löffler ◽  
Daniel Gröbel ◽  
Johannes Henneberg
Keyword(s):  
Metal Forming ◽  
Material Flow ◽  
Simultaneous Occurrence ◽  
Tribological Behaviour ◽  
Forming Process ◽  
Functional Elements ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Main Challenge ◽  
Functional Components

Highly-integrated and closely-tolerated functional components can be produced by sheet-bulk metal forming which is the application of bulk forming operations on sheet metals. These processes are characterized by a successive and/or simultaneous occurrence of different load conditions such as stress and strain states which reduce the geometrical accuracy of the functional elements. Thus, one main challenge within sheet-bulk metal forming is the identification of methods to control the material flow and thus to improve the product quality. One suitable approach is to control the material flow by local modifications of the tribological conditions. Within this study requirements regarding the needed adaption of the tribological conditions for a specific sheet-bulk metal forming process were defined by numerical investigations. The results reveal that a local increase of the friction leads to an improved die filling of the functional elements. Based on these results abrasive blasting as a method to modify the tool surface and thus influencing the tribological behaviour was investigated. For the determination of the tribological mechanism of blasted tool surfaces, the influence of different blasting media as well as blasting pressures on the surface integrity and the friction were determined. The correlations between surface properties and friction conditions were used to derive the mechanisms of blasted tool surfaces.

Principle and Simulation Study on Multi Point-Single Point Incremental Combined Forming for Sheet Metal

2009 ◽  
Vol 626-627 ◽  
pp. 273-278 ◽  
Author(s):  
X.J. Li ◽  
Ming Zhe Li ◽  
C.G. Liu ◽  
Zhong Yr Cai
Keyword(s):  
Sheet Metal ◽  
Single Point ◽  
Experimental Result ◽  
Work Piece ◽  
The Novel ◽  
Forming Process ◽  
Explicit Finite Element ◽  
Forming Defect ◽  
Forming Technology ◽  
Elastic Cushion

Based on Multi-Point (MP) forming technology and Single-Point Incremental (SPI) forming technology, MP-SPI combined forming method for sheet metal is proposed, the principle and two different forming techniques are illustrated firstly. Then the paper is focused on numerical analysis for the novel forming technique with explicit Finite Element (FE) algorithm. During simulation of spherical work-piece, dimpling occurs as a main forming defect in MP-SPI combined forming process. Simulation results show that the dimpling defect can be suppressed effectively by using elastic cushion. An appropriate thickness of elastic cushion is necessary to prevent dimpling. And also the deformation of the work-piece is sensitive to the shape of elastic cushion. The combined forming test shows that the numerical simulation result is closed to the experimental result.

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