scholarly journals Research on Hydroforming Micro-Sized Spiral Pipe With Equal Wall Thickness

2021 ◽  
Author(s):  
Changshuai Shi ◽  
Jinping Li ◽  
Xiaohua Zhu
Keyword(s):  
Wall Thickness ◽  
Uniaxial Tensile ◽  
Uniaxial Tensile Test ◽  
Processing Temperature ◽  
Hydraulic Pressure ◽  
Outer Diameter ◽  
Forming Process ◽  
Spiral Tube ◽  
Positive Displacement ◽  
Different Temperatures

Abstract The positive displacement motor is currently the most widely used downhole power tool. In order to reduce the cost of drilling and exploration, small boreholes have been used to replace conventional boreholes. The working conditions are complex, so a high-performance positive displacement motor for micro-holes is required. In order to solve the problem of the difficulty in processing the inner spiral surface of the small size and large aspect ratio, the tiny size spiral tube stator is proposed in this paper and the normal temperature and hot state hydroforming of the small size spiral tube is proposed in this paper. The material is 42crmo, and the uniaxial tensile test is carried out at different temperatures. According to the material mechanical properties experiment and the forming process, the finite element model of the hydroformed spiral tube at different temperatures is established. The study found that the suitable tube size is 48mm in outer diameter, 5.5mm in wall thickness, and 1405mm in length. When the processing temperature is 700℃, the hydraulic pressure required for full expansion of the spiral tube is only 70MPa, and the rebound of the spiral tube is very small. The minimum wall thickness is the maximum of 4.31mm, and the maximum wall thickness is the minimum of 5.356mm, and the wall thickness distribution is relatively uniform. The maximum plastic strain of the spiral tube is 0.65, so the damage to the material during the forming process is small, and when the processing temperature is 700℃, the quality of the spiral tube is better.

EFFECT OF HYDRAULIC PRESSURE ON WARM HYDRO MECHANICAL DEEP DRAWING OF MAGNESIUM ALLOY SHEET

2009 ◽  
Vol 23 (06n07) ◽  
pp. 1975-1980 ◽  
Author(s):  
WEI LIU ◽  
LINZHI WU ◽  
SHIJIAN YUAN
Keyword(s):  
Magnesium Alloy ◽  
Deep Drawing ◽  
Experimental Studies ◽  
Alloy Sheet ◽  
Forming Limit ◽  
Uniaxial Tensile ◽  
Uniaxial Tensile Test ◽  
Hydraulic Pressure ◽  
Different Temperatures ◽  
Hydraulic Bulging

The uniaxial tensile test and hydraulic bulging test of AZ31 magnesium alloy sheets were applied to study the influence of temperature on the material properties and obtain the forming limit curves at different temperatures. Numerical simulations of warm hydro mechanical deep drawing were carried out to investigate the effect of hydraulic pressure on the formability of a cylindrical cup, and the simplified hydraulic pressure profiles were used to simulate the loading procedure of hydraulic pressure. The optimal hydraulic pressure at different temperatures were given and verified by experimental studies at temperature 100°C and 170V.

scholarly journals Performance of Thermo-Mechanically Processed AA7075 Alloy at Elevated Temperatures—From Microstructure to Mechanical Properties

Metals ◽  
2020 ◽  
Vol 10 (7) ◽  
pp. 884 ◽  
Author(s):  
Seyed Vahid Sajadifar ◽  
Emad Scharifi ◽  
Ursula Weidig ◽  
Kurt Steinhoff ◽  
Thomas Niendorf
Keyword(s):  
Mechanical Properties ◽  
Elevated Temperatures ◽  
Tensile Tests ◽  
Uniaxial Tensile ◽  
Forming Process ◽  
Softening Mechanism ◽  
Rate Dependent ◽  
Heat Treated ◽  
Different Temperatures ◽  
Die Forming

This study focuses on the high temperature characteristics of thermo-mechanically processed AA7075 alloy. An integrated die forming process that combines solution heat treatment and hot forming at different temperatures was employed to process the AA7075 alloy. Low die temperature resulted in the fabrication of parts with higher strength, similar to that of T6 condition, while forming this alloy in the hot die led to the fabrication of more ductile parts. Isothermal uniaxial tensile tests in the temperature range of 200–400 °C and at strain rates ranging from 0.001–0.1 s−1 were performed on the as-received material, and on both the solution heat-treated and the thermo-mechanically processed parts to explore the impacts of deformation parameters on the mechanical behavior at elevated temperatures. Flow stress levels of AA7075 alloy in all processing states were shown to be strongly temperature- and strain-rate dependent. Results imply that thermo-mechanical parameters are very influential on the mechanical properties of the AA7075 alloy formed at elevated temperatures. Microstructural studies were conducted by utilizing optical microscopy and a scanning electron microscope to reveal the dominant softening mechanism and the level of grain growth at elevated temperatures.

External high-pressure forming of metal spiral tube of equal wall thickness

2020 ◽  
pp. 095440892096778
Author(s):  
Changshuai Shi ◽  
Jinping Li ◽  
Juan Deng ◽  
Xiaohua Zhu
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
High Pressure ◽  
Wall Thickness ◽  
Oil And Gas ◽  
Element Model ◽  
304 Stainless Steel ◽  
Spiral Tube ◽  
Positive Displacement ◽  
Tensile Experiment

Positive displacement motors are widely used underground power tools in oil and gas extraction. In order to solve the problems of the short life of the conventional positive displacement motor and the difficulty of machining the constant wall positive displacement motor, this paper proposes a metal bush stator. Based on theoretical analysis and tensile experiment of 304 stainless steel, a finite element model of an external high-pressure forming equal-wall-thickness metal spiral tube was established. The finite element method is used to study the external high pressure forming spiral tube with equal wall thickness. According to the results of the numerical simulation, we choose the tube blank with the inner diameter of 88 mm×the wall thickness of 3 mm for the experiment of external high pressure forming spiral tube. The result of the experiment is that the inner and outer surfaces of the metal spiral tube are smooth, and the spiral tube has no wrinkles or cracks. The maximum gap between the spiral tube and the mold is 0.12 mm, and the inner surface of the spiral tube is close to the mold. The maximum gap are at the transition of convex arc and concave arc. The minimum wall thickness and the maximum wall thickness of the spiral tube are 2.6 mm and 3.205 mm, respectively. The quality of the spiral tube is better when the inner circumference length of the tube (D2)/the contour line circumference (D1) of the mold is 0.974. The experimental results are in good agreement with the numerical simulation results. We have designed an assembled mold, which can be removed smoothly after the experiment. The research results of this paper have important engineering significance for improving the working performance of positive displacement motors.

Analysis and Calculation of the Art of Internal High Pressure Forming

2013 ◽  
Vol 746 ◽  
pp. 374-379
Author(s):  
Ying Liu ◽  
Feng Xu ◽  
Bing De Wang
Keyword(s):  
High Pressure ◽  
Wall Thickness ◽  
New Technology ◽  
Elastic Force ◽  
Stress And Strain ◽  
Hydraulic Pressure ◽  
Forming Process ◽  
Incompressibility Condition ◽  
Theoretical Support ◽  
Light Components

nternal high pressure forming is a new technology producing hollow light components. Due to the process of internal high pressure forming is very complicated with many factors, the dissertation will focus on the use of plastic-elastic force theory to acquire the hydraulic pressure needed and the tubes wall thickness in the final forming fillet. Based on the assumption of volume's incompressibility condition, we analyze and calculate the stress and strain of the tubes wall. Finally we estimate the formula of the hydraulic pressure needed in the forming process. The whole work can offer a concise formula to engineer in the infancy of designing. And it also is the great theoretical support to the development of the internal high pressure forming.

Mechanical Response of Ti-6Al-4V Alloy on Deformation at Moderate Temperatures

2013 ◽  
Vol 549 ◽  
pp. 311-316 ◽  
Author(s):  
Marion Merklein ◽  
Hinnerk Hagenah ◽  
Markus Kaupper ◽  
Adam Schaub
Keyword(s):  
Titanium Alloy ◽  
Elevated Temperatures ◽  
Mechanical Response ◽  
Material Behavior ◽  
High Yield ◽  
Uniaxial Tensile ◽  
Uniaxial Tensile Test ◽  
Forming Process ◽  
Element Analysis ◽  
Specific Strength

Due to beneficial characteristics such as high specific strength, corrosion resistance and biocompatibility Ti-6Al-4V alloy has become the most important industrially produced titanium alloy during the last decades. Commonly used for aerospace technology and medical products, nowadays Ti-6Al-4V covers 50% of the worldwide produced titanium alloy parts. Different deformation operations as forging and casting as well as machining are used to shape titanium alloy components. For sheet metals, cost and time of fabrication can be reduced significantly via the near net shape technology sheet metal forming. Materials such as the α + β alloy Ti-6Al-4V with high yield stress and comparatively low elastic modules need to be formed at elevated temperatures to increase their formability. Numerical simulations are applied to calculate the forming behavior during the process and conclude the characteristics of the shaped part. Therefore in this paper the mechanical behavior of this titanium alloy is investigated by uniaxial tensile test within elevated temperatures ranging from 250 to 500 °C. Finally, the experimental results are adapted to models which predict the flow response in order to describe material behavior in finite element analysis of the forming process.

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.

The Effect of Forming Speed on the Formability of a Zr-Based Bulk Metallic Glass

2015 ◽  
Vol 1088 ◽  
pp. 265-271 ◽  
Author(s):  
Wu Xiao ◽  
Jian Jun Li ◽  
Zhi Zhen Zheng ◽  
Jin Yang Li
Keyword(s):  
Metallic Glass ◽  
Bulk Metallic Glass ◽  
Wall Thickness ◽  
Supercooled Liquid ◽  
Supercooled Liquid Region ◽  
Outer Diameter ◽  
Liquid Region ◽  
Forming Process ◽  
Element Analysis ◽  
Extrusion Forming

Taking cup-shaped part (outer diameter D and wall thickness are chosen as 2.2 mm and 0.05 mm, respectively) as an example, the micro-back-extrusion forming process of a Zr55Cu30 Al10Ni5 bulk metallic glass (BMG) in its supercooled liquid region was studied by using finite-element analysis (FEM) and experiment. The effect of forming speed on the formability was analyzed based on the extrusion load, the rheological behavior of the material and the microstructure of the formed parts. It was found that while the forming speed is below than 4 μm/s, the extrusion load increases obviously with the increasing in forming speed, otherwise, the BMG will follow non-newtonian flow and the forming load is insensitive to the forming speed. The parts fabricated at 2 μm/s are obviously crystallized due to the long retention time of metallic glasses at high temperature, a higher forming speed is benefit to enhancing the formability if the BMG. On this basis, micro cup-shaped parts with only 0.05 mm in wall thickness are successfully extruded.

Hydro-Mechanical Deep Drawing Simulation and Preparation of Novel Al-Li Alloy Irregular Cups

2015 ◽  
Vol 1089 ◽  
pp. 337-340
Author(s):  
Juan Ling ◽  
Hua Guan Li ◽  
Jie Tao ◽  
Xun Zhong Guo ◽  
Hui Wang ◽  
...  
Keyword(s):  
Thickness Distribution ◽  
True Stress ◽  
Experimental Results ◽  
Uniaxial Tensile ◽  
Uniaxial Tensile Test ◽  
Forming Process ◽  
Element Analysis ◽  
Aluminum Lithium Alloy ◽  
Analysis Technique ◽  
Aluminum Lithium

The true stress-strain curves of 2198-T3 aluminum-lithium alloy in three different orientations (0°,45° and 90°) were measured by uniaxial tensile test. Finite element analysis technique was used to simulate the forming process of irregular cup, and the hydro forming experiments were conducted with YB32-100t press machine. The results showed that the key forming parameter-n values were similar in three orientations. Simulation results illustrated that the thickness of the blank reached the lowest value at the round corner. Experimental results verified friction was a significant factor to manufacture a qualified competent. Meanwhile, the experimental results agreed well with the simulation ones. The practical thickness distribution of 2198-T3 irregular cup along the section line was coincided with simulation.

Instrumentation and Control of a Bulge Test on a Superplastic Pb-Sn Alloy

2012 ◽  
Vol 735 ◽  
pp. 224-231
Author(s):  
Erick Petta Marinho ◽  
Alberto Sakata ◽  
Erika Fernanda Prados ◽  
Gilmar Ferreira Batalha
Keyword(s):  
Strain Rate ◽  
Superplastic Forming ◽  
Uniaxial Tensile ◽  
Bulge Test ◽  
Uniaxial Tensile Test ◽  
Biaxial Test ◽  
Biaxial Testing ◽  
Forming Process ◽  
Set Up ◽  
And Control

Superplasticity is characterized by high elongations under a high strain rate sensibility, and it’s variation with strain rate, temperature and grain size. This parameter is often obtained from uniaxial tensile test. However, superplastic deformation is a biaxial process; hence there is a need to develop a way to get this parameter in a biaxial test. This work aims to set up the instrumentation to record and control a biaxial superplastic forming in a Pb-Sn alloy. The control system project has been divided into tracking variables: strain and pressure. The instrumentation is able to predict the breaking point at the beginning of the superplastic forming process from biaxial testing.

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