Investigations on Orbital Forming of Sheet Metals to Manufacture Tailored Blanks with a Defined Sheet Thickness Variation

2013 ◽  
Vol 769 ◽  
pp. 157-164 ◽  
Author(s):  
Raoul Plettke ◽  
Simon Opel
Keyword(s):  
Design Of Experiments ◽  
Sheet Thickness ◽  
Thickness Variation ◽  
Surface Model ◽  
Forming Process ◽  
Cold Forming ◽  
Mould Filling ◽  
Tailored Blanks ◽  
Orbital Forming ◽  
Cutting Processes

Orbital forming is an incremental bulk cold forming process with many advantages. It can produce net-shape or near-net-shape parts that have superior mechanical properties due to work hardening compared to manufacturing with cutting processes or hot forming. In this work the orbital forming process is employed in a closed-die configuration. A rising of the material thickness in the outer areas of a circular sheetmetal blank is enabled by preventing the lateral material flow. The main effects and subsequently the effects of the interaction of parameters were investigated by a two-step design of experiments. A screening plan was used to identify the statistically relevant parameters. The effects were then studied in a subsequent central-composite design of experiments. With the measured data a nonlinear response-surface model was parameterized to describe the dependency of the mould filling on the investigated process parameters. This model was validated experimentally and showed a good agreement to reality. Additionally a new concept for the tool system was developed and investigated. The form-defining cavity can be changed from the upper punch to the counterpunch.

The Influence of the UOE Forming Process on Material Properties and Collapse of Deepwater Linepipe

2009 ◽  
Author(s):  
Chris Timms ◽  
Luciano Mantovano ◽  
Hugo A. Ernst ◽  
Rita Toscano ◽  
Duane DeGeer ◽  
...  
Keyword(s):  
Finite Element ◽  
Material Properties ◽  
Manufacturing Process ◽  
Thermal Ageing ◽  
Full Scale ◽  
Sensitivity Analyses ◽  
Thickness Variation ◽  
Forming Process ◽  
Cold Forming ◽  
Pipe Manufacturing

It has been demonstrated in previous work that, for deepwater applications, the cold forming process involved in UOE pipe manufacturing significantly reduces pipe collapse strength. To improve the understanding of these effects, Tenaris has embarked on a program to model the stages of the UOE manufacturing process using finite element methods. Previous phases of this work formulated the basis for model development and described the 2D approach taken to model the various stages of manufacture. More recent developments included some modeling enhancements, sensitivity analyses, and comparison of predictions to the results of full-scale collapse testing performed at C-FER. This work has shown correlations between manufacturing parameters and collapse pressure predictions. The results of the latest phase of the research program are presented in this paper. This work consists of full-scale collapse testing and extensive coupon testing on samples collected from various stages of the UOE pipe manufacturing process including plate, UO, UOE, and thermally-aged UOE. Four UOE pipe samples manufactured with varying forming parameters were provided by Tenaris for this test program along with associated plate and UO samples. Full-scale collapse and buckle propagation tests were conducted on a sample from each of the four UOE pipes including one that was thermally aged. Additional coupon-scale work included measurement of the through-thickness variation of material properties and a thermal ageing study aimed at better understanding UOE pipe strength recovery. The results of these tests will provide the basis for further refinement of the finite element model as the program proceeds into the next phase.

Optimization of Incremental Sheet Metal Forming Parameters by Design of Experiments

2014 ◽  
Vol 527 ◽  
pp. 111-116 ◽  
Author(s):  
Sunil D. Majagi ◽  
G. Chandramohan
Keyword(s):  
Design Of Experiments ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Surface Model ◽  
Forming Process ◽  
Incremental Sheet Metal Forming ◽  
Metal Forming Process ◽  
Process Factors ◽  
Yield Responses

The purpose of the paper is to investigate the dependency of various parameters on metal forming process using mathematical models. The incremental sheet metal forming process was studied using Box–Behnken design of experiments along with response from surface methodology analysis. In the study process factors namely feed rate, speed and coolant were analysed to understand the effect on the surface roughness, percentage (%) of thickness reduction, grain size and hardness of the Aluminium (Al) sheet metal, were examined after forming. The surface model analysis predicts that all four responses of the incremental forms show very strong correlation with the experimental results. The optimized process of incremental forming that runs on maintained levels of predicted factors, yield responses very close to that predicted from the model.

Flexible Rolling of Process Adapted Semi-Finished Parts and its Application in a Sheet-Bulk Metal Forming Process

2015 ◽  
Vol 639 ◽  
pp. 259-266 ◽  
Author(s):  
Philipp Hildenbrand ◽  
Thomas Schneider ◽  
Marion Merklein
Keyword(s):  
Sheet Thickness ◽  
Rolling Process ◽  
Forming Process ◽  
Flexible Rolling ◽  
Bulk Forming ◽  
Tailored Blanks ◽  
Metal Forming Process ◽  
Thickness Variations ◽  
Process Strategy ◽  
Functional Components

By applying bulk forming processes on sheet metals, thin-walled functional components with locally restricted wall thickness variations can be manufactured by forming operations. Using tailored blanks with a modified sheet thickness gradient instead of conventional blanks, an efficient controlling of the material flow can be achieved. One possible process to manufacture these semi-finished parts is a flexible rolling process. Based on an established process strategy new results for steels of differing strength and work-hardening behavior are presented in this paper. The influences of each material on the resulting process forces and blank properties regarding the same target geometry are discussed. The tailored blanks are hereby analyzed by their geometrical dimensions, like sheet thickness, and their mechanical properties, e.g. hardness distribution. Additionally, the possibilities of processing these tailored blanks in a deep-drawing and upsetting process are presented with a hereby focus on the residual formability of the tailored blanks.

Manufacturing of Sheet Metal Components with Variants Using Process Adapted Semi-Finished Products

2012 ◽  
Vol 504-506 ◽  
pp. 1023-1028 ◽  
Author(s):  
Marion Merklein ◽  
Raoul Plettke ◽  
Thomas Schneider ◽  
Simon Opel ◽  
Daniel Vipavc
Keyword(s):  
Sheet Metal ◽  
Sheet Thickness ◽  
Forming Process ◽  
Local Loads ◽  
Bulk Forming ◽  
Orbital Forming ◽  
Metal Products ◽  
2D And 3D ◽  
Process Combination ◽  
Specific Control

Manufacturing of functional sheet metal products by forming can be realised with the application of conventional bulk forming operations on sheet metals. The challenges of those sheet bulk metal forming processes are high resulting forming forces and the demand on a specific control of material flow. To meet these challenges well-directed thinning of blanks as well as accumulations of material to form functional elements is employed. Due to local loads, simultaneous 2D and 3D stress and strain states occur. Process adapted semi-finished products, containing a defined sheet thickness characteristic, are formed in the presented work by the technologies upsetting and orbital forming. Orbital forming is an incremental bulk forming operation to decrease the forming zone extension and consequently the required process force. Afterwards a process combination of deep drawing and upsetting in order to manufacture a cup-shaped workpiece with external gearing is presented. The results of this integrated single-stage forming process are discussed and subsequently the potential to enhance the process limits is shown by using process adapted semi-finished products.

Grain Size Modification by Micro Rotary Swaging

2015 ◽  
Vol 651-653 ◽  
pp. 627-632 ◽  
Author(s):  
Svetlana Ishkina ◽  
Bernd Kuhfuss ◽  
Christian Schenck
Keyword(s):  
Grain Size ◽  
Longitudinal Section ◽  
Forming Process ◽  
Boundary Area ◽  
Cold Forming ◽  
Flat Surfaces ◽  
Rotary Swaging ◽  
2D Simulation ◽  
Physical Tests ◽  
Formed Part

Rotary swaging is a well established cold forming process e.g. in the automotive industry. In order to modify the material properties by swaging systematically, a new process of swaging with asymmetrical strokes of the forming dies is investigated. The newly developed tools feature flat surfaces and do not represent the geometry of the formed part as in conventional swaging. Numerical simulation and physical tests are carried out with special regard to the resulting geometry, mechanical properties and the microstructure. During these tests copper wires with diameter d0=1 mm are formed. Regarding the microstructure in the longitudinal section of formed specimens, elongation of grains in the central part and grain size reduction in the boundary area are observed. Furthermore, this approach opens up new possibilities to configure the geometry of wires. 2D-simulation is applied and discussed in the paper to investigate change of the processed geometry (cross-section) and shear strain distribution during the rotary swaging process.

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 Deformation Characteristics and Microstructure Analysis of Aluminum Alloy Component with Complex Shape by Cold Orbital Forming

Metals ◽  
2021 ◽  
Vol 11 (5) ◽  
pp. 808
Author(s):  
Wei Feng ◽  
Chaoyi Jin ◽  
Jiadong Deng ◽  
Wuhao Zhuang
Keyword(s):  
Aluminum Alloy ◽  
Complex Shape ◽  
Fe Simulation ◽  
Effective Strain ◽  
Electron Back Scatter Diffraction ◽  
Main Body ◽  
Deformation Characteristics ◽  
Alloy Component ◽  
Forming Process ◽  
Orbital Forming

This work aimed to study the deformation characteristics and microstructure of AA6063 aluminum alloy component with complex shape manufactured by cold orbital forming processing. The material flowing behavior was analyzed by Finite Element (FE) simulation and forming experiments were carried out using bar blank with different lengths. The microstructure of the boss zone cut from the formed samples was observed using scanning electron microscopy (SEM) and electron back-scatter diffraction (EBSD). FE simulation and experiment results both showed the aluminum base can be formed using cold orbital forming process. The distributions of the effective strain of the component with different blank lengths were almost the same, and the effective strain was bigger at the boss and the flash as the forming finished. The material flow is complex, especially in the boss, and the folding defect was observed at the root of the boss. The distribution of Mg2Si strengthening precipitate is more homogeneous in the matrix, has a different shape, and shows directivity at different position of boss zone. The grains are elongated, and the extent is different at different positions of the boss zone after cold orbital forming, and the crystal orientation discrepancy is smaller in the component main body and bigger in the boss zone. Subsequent forming process and blank optimization need to be further researched to improve forming quality.

Machine Learning Acoustic Emission Based Monitoring of Cold Forging for Smart Manufacturing: A Review

2021 ◽  
Vol 2 (3) ◽  
Keyword(s):  
Machine Learning ◽  
Acoustic Emission ◽  
Product Quality ◽  
High Speed ◽  
High Rate ◽  
Cold Forging ◽  
Smart Manufacturing ◽  
Forming Process ◽  
Cold Forming ◽  
Effective Manner

Cold forging is a high-speed forming technique used to shape metals at near room temperature. and it allows high-rate production of high strength metal-based products in a consistent and cost-effective manner. However, cold forming processes are characterized by complex material deformation dynamics which makes product quality control difficult to achieve. There is no well defined mathematical model that governs the interactions between a cold forming process, material properties, and final product quality. The goal of this work is to provide a review for the state of research in the field of using acoustic emission (AE) technology in monitoring cold forging process. The integration of AE with machine learning (ML) algorithms to monitor the quality is also reviewed and discussed. It is realized that this promising technology didn’t receive the deserving attention for its implementation in cold forging and that more work is needed.

Research of Characteristic of Wrinkling in Cold Forming Process for Ship Frame Part Based on Numerical Simulation

2015 ◽  
Author(s):  
Pei-Yong Li ◽  
◽  
Jun-jie Song ◽  
Cheng-fang Wang ◽  
Yun-sheng Mao ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Forming Process ◽  
Cold Forming

Dieless Water Jet Incremental Micro-Forming

2018 ◽  
Author(s):  
Yi Shi ◽  
Jian Cao ◽  
Kornel F. Ehmann
Keyword(s):  
Process Parameters ◽  
Thin Shell ◽  
High Speed ◽  
Single Point ◽  
Sheet Thickness ◽  
Water Jet ◽  
Micro Forming ◽  
Forming Process ◽  
Thin Foils ◽  
High Pressure Water Jet

Compared to the conventional single-point incremental forming (SPIF) processes, water jet incremental micro-forming (WJIMF) utilizes a high-speed and high-pressure water jet as a tool instead of a rigid round-tipped tool to fabricate thin shell micro objects. Thin foils were incrementally formed with micro-scale water jets on a specially designed testbed. In this paper, the effects on the water jet incremental micro-forming process with respect to several key process parameters, including water jet pressure, relative water jet diameter, sheet thickness, and feed rate, were experimentally studied using stainless steel foils. Experimental results indicate that feature geometry, especially depth, can be controlled by adjusting the processes parameters. The presented results and conclusions provide a foundation for future modeling work and the selection of process parameters to achieve high quality thin shell micro products.

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