Process Planning for the Lateral Extrusion of a Pipe with a Lost Core

2017 ◽  
Vol 735 ◽  
pp. 3-7
Author(s):  
Takahiro Ohashi ◽  
Wataru Kimura
Keyword(s):  
Process Planning ◽  
Pipe Material ◽  
Trial And Error ◽  
Forming Process ◽  
Extrusion Speed ◽  
Lateral Extrusion ◽  
Truncated Cone ◽  
Longitudinal Length ◽  
Pipe Radius ◽  
Free Bulging

In this paper, the authors discuss process planning for the lateral extrusion of a pipe with a lost core. In this process, maximum longitudinal length of the bulged part is restricted by the balance of the extrusion speed of the material and the lost core. In the free bulging condition, longitudinal length is limited to the pipe radius, because the extrusion speed of the core is slower than that of the pipe material when the longitudinal length of the bulged part is longer. The authors designed a two-stage forming process using the transit shape of a truncated cone to solve this problem. The dimensions of the truncated cone were estimated through trial-and-error using a commercial FEM simulator and considering the stretch effect for wrinkles of the pipe by deformation and traveling of the lost core. Finally, the authors conducted experiments to confirm the design’s validity. As a result, a longer longitudinal length of the bulged part than the pipe radius was successfully obtained.

Querfließpressen und Verschieben*/Lateral extrusion and shifting

2017 ◽  
Vol 107 (10) ◽  
pp. 708-713
Author(s):  
M. Prof. Liewald ◽  
L. Pasler
Keyword(s):  
Numerical Simulation ◽  
New Technology ◽  
Cold Forging ◽  
Forming Process ◽  
Tensile Stresses ◽  
Lateral Extrusion

Mit dem neu entwickelten Verfahren, das Querfließpressen mit gleichzeitigem Verschieben kombiniert, lassen sich exzentrische Wellen oder kurbelwellenartige Bauteile durch Kaltfließpressen herstellen. Der Vorteil im Unterschied zur Verfahrenskombination von Stauchen und anschließendem Verschieben ist, dass das Querfließpressen ein Nachführen von Material während des Umformprozesses in die Umformzone ermöglicht. Aufgrund der verfahrensbedingten geringeren Zugspannungen in der Kurbelwange sind mit dem neuen Verfahren erweiterte Verfahrensgrenzen beim Versatz zu erwarten. Dieser Fachbeitrag beschreibt das Verfahrensprinzip, das Werkzeugkonzept und die numerische Auslegung des Prozesses.   The new technology of combined lateral extrusion and simultaneous shifting allows producing eccentric shafts or crankshaft-like components by cold forging. The advantage of lateral extrusion compared to an upsetting and subsequent shifting is the constant web thickness. For this, material is pushed into the forming zone during the forming process. It is expected that this will result in lower tensile stresses and thus lower damage in the crankshaft web. This paper describes the process, tooling concept and numerical simulation of the combined lateral extrusion and shifting process.

scholarly journals Acquisition and Evaluation of Theoretical Forming Limit Diagram of Al 6061-T6 in Electrohydraulic Forming Process

Metals ◽  
2019 ◽  
Vol 9 (4) ◽  
pp. 401 ◽  
Author(s):  
Min-A Woo ◽  
Woo-Jin Song ◽  
Beom-Soo Kang ◽  
Jeong Kim
Keyword(s):  
Strain Rate ◽  
Split Hopkinson Pressure Bar ◽  
Forming Limit Diagram ◽  
Forming Limit ◽  
Forming Process ◽  
Electrohydraulic Forming ◽  
Al 6061 ◽  
Shpb Test ◽  
Strain Rate Hardening ◽  
Free Bulging

The current study examines the forming limit diagram (FLD) of Al 6061-T6 during the electrohydraulic forming process based on the Marciniak–Kuczynski theory (M-K theory). To describe the work-hardening properties of the material, Hollomon’s equation—that includes strain and strain rate hardening parameters—was used. A quasi-static tensile test was performed to obtain the strain-hardening factor and the split-Hopkinson pressure bar (SHPB) test was carried out to acquire the strain rate hardening parameter. To evaluate the reliability of the stress–strain curves obtained from the SHPB test, a numerical model was performed using the LS–DYNA program. Hosford’s yield function was also employed to predict the theoretical FLD. The obtained FLD showed that the material could have improved formability at a high strain rate index condition compared with the quasi-static condition, which means that the high-speed forming process can enhance the formability of sheet metals. Finally, the FLD was compared with the experimental results from electrohydraulic forming (EHF) free-bulging test, which showed that the theoretical FLD was in good agreement with the actual forming limit in the EHF process.

Forming Mechanism of Folding Defect within Closed Die Forming Car Steering Knuckle

2011 ◽  
Vol 704-705 ◽  
pp. 240-244 ◽  
Author(s):  
De Ying Zhao ◽  
Lian Dong Zhang ◽  
Li Na Sun
Keyword(s):  
Extrusion Process ◽  
Steering System ◽  
Forming Process ◽  
Forming Mechanism ◽  
Lateral Extrusion ◽  
Folding Defect ◽  
Material Utilization ◽  
Punch Shape ◽  
Die Forming ◽  
Shape And Size

Steering knuckle is the key part of vehicle steering system. The forming technology combined closed die pre-forging with open finish-forging has some advantages such as higher material utilization ratio and lower forming forces and so on. While simulating the closed die extrusion forming process of car steering knuckle, folding defect emerges on the contact area of Branch I and lower punch in the lateral extrusion process. The forming mechanism of the folding defect is studied by numerical simulations and experiments, which mainly consider the influence of lower punch shape and size, extrusion speed and friction conditions to folding length. The results show that the main factors that affect folding defects are the lower punch shape and size. Keywords: steering knuckle, folding defect, closed die forming, numerical simulation, experiment study

Reliability Analysis of the Tube Hydroforming Process Based on Forming Limit Diagram

2005 ◽  
Vol 128 (3) ◽  
pp. 402-407 ◽  
Author(s):  
Bing Li ◽  
Don R. Metzger ◽  
Tim J. Nye
Keyword(s):  
Automotive Industry ◽  
Metal Forming ◽  
Tube Hydroforming ◽  
Forming Limit Diagram ◽  
Probability Of Failure ◽  
Alternative Methods ◽  
Forming Limit ◽  
Forming Process ◽  
Hydroforming Process ◽  
Free Bulging

Tube hydroforming is an attractive manufacturing process in the automotive industry because it has several advantages over alternative methods. In order to determine the reliability of the process, a new method to assess the probability of failure is proposed in this paper. The method is based on the reliability theory and the forming limit diagram, which has been extensively used in metal forming as the criteria of formability. From the forming limit band in the forming limit diagram, the reliability of the forming process can be evaluated. A tube hydroforming process of free bulging is then introduced as an example to illustrate the approach. The results show this technique to be an innovative approach to avoid failure during tube hydroforming.

Research on Workpiece Deformation in Electromagnetic Forming Process with Finite Element Method

2014 ◽  
Vol 989-994 ◽  
pp. 2702-2704
Author(s):  
Chang Peng ◽  
Li Qiu ◽  
Ke Shen Gong ◽  
Ding Jun Wang
Keyword(s):  
Electromagnetic Coupling ◽  
Basic Structure ◽  
Electromagnetic Forming ◽  
Forming Process ◽  
Spiral Coil ◽  
Electromagnetic Structure ◽  
Sequential Coupling ◽  
Flat Spiral ◽  
Free Bulging ◽  
Center Area

Electromagnetic forming is a kind of processing technology that use lorentz force to make rapid prototyping of metal workpiece, which can significantly improve the metal forming performance,and it is expected to become an emerging technology that alternative to traditional machining to process light alloy materials. Based on the understanding the basic structure of the electromagnetic coupling on the basis of physical process of electromagnetic forming, this article adopt ANSYS sequential coupling method to simulate the electromagnetic coupling process of electromagnetic structure, and analysis of tube electromagnetic forming and plate of workpiece in the process of free bulging deformation behavior. The solenoid coil tubing have an axis of symmetry due to bulging, and it’s electromagnetism load and constraint has symmetry, so its formability is uniform in hoop direction. When the plank free bulge, the distribution of the electromagnetic force caused by the flat spiral coil is not uniform,and the artifacts accelerate fastest in the part of the radius of coil 1/2, but the center area of the workpiece’s forming height is highest.

scholarly journals Defect Prediction at The Superplastic Forming Process of The Bipolar Plate by Simulation

2018 ◽  
Vol 3 (1) ◽  
pp. 49
Author(s):  
Ismi Choirotin ◽  
Moch. Agus Choiron
Keyword(s):  
Effective Stress ◽  
Superplastic Forming ◽  
Bipolar Plate ◽  
Thickness Reduction ◽  
Trial And Error ◽  
Forming Process ◽  
Maximum Thickness ◽  
Forming Temperature ◽  
Trial And Error Method ◽  
Error Method

 Improper parameter setting at the bipolar plate forming by superplastic process will outcome damage to the final workpiece. By employing computer simulation, the defect at the bipolar plate could be predicted close to the maximum thickness reduction and the effective stress data. Simulate the fabrication of bipolar plate by a number of forming temperature (350 – 450 °C) and air pressure (0.25 – 1 MPa) utilize Ansys, resulting maximum thickness reduction and effective stress occurred at 450 °C and 1 MPa. Make reference to the result, the bipolar plate didn’t expose any deficiency with 36.75% maximum thickness reduction. Have recourse to simulation will abbreviate the trial and error method as of the production process will more effective and efficient in terms of time and cost

Numerical Evaluation and Influence of Product Quality and its defects Measures on the drawing of Stainless Steel Cross Member for Automobiles

2019 ◽  
Vol 11 (1) ◽  
Author(s):  
S.P. Sundar Singh Sivam ◽  
Ganesh Babu Loganathan ◽  
K. Saravanan ◽  
V.G. Umasekar ◽  
S. Rajendrakumar
Keyword(s):  
Metal Forming ◽  
Trial And Error ◽  
Financial Loss ◽  
Forming Process ◽  
Strict Adherence ◽  
Industrial Enterprises ◽  
Forming Parameters ◽  
Cross Member ◽  
Quality Of Products

Industrial enterprises increasingly demand optimum quality of products keeping in consideration a strict adherence where forming parameters are concerned. As far as incorporating the vital forming process upon an assortment of materials is concerned, it has grown excruciatingly challenging for industrial enterprises for laying out the adequately precise and suitable parameters. The flaws that are engendered during the process of sheet metal forming are inevitable. Flaws of this nature can be, however, kept within minimal proportions by introducing variations into the process parameters by Trial and Error methodology. This evidently results in a subsequent financial loss, not to mention an irrevocable loss of time and material. Dynaform simulation of defects combined with optimization is carried out with the help of Minitab. This method, as can be conjectured with considerable ease, yields optimum results, for it replaces much to our convenience the need for specialist industrial expertise besides leading to considerable savings in cost, time and material. This study would optimize the SS304sheet metal forming parameters FLD, thickness and thinning with three input parameters, namely, the lower binder force, tool travel velocity and binder close velocity.

Experimental Study on the Density of Fish Feed Pellets

2014 ◽  
Vol 668-669 ◽  
pp. 1679-1682
Author(s):  
Xin Song ◽  
Yan Cong Li ◽  
Zhi Sheng Wan ◽  
Shuang Shuang Zheng
Keyword(s):  
Structural Parameters ◽  
Fish Feed ◽  
Forming Process ◽  
Extrusion Speed ◽  
Density Control ◽  
Study Results ◽  
Experiment Method ◽  
Two Factors ◽  
Pellet Density ◽  
Extrusion Forming

For the problem of pellet density control in the fish feed extrusion forming process, the influence of extrusion speed, the depth of die hole and the interaction of the two factors on feed pellet density was studied by experiment method. The study results own good application value because as theoretical basis they can be used to determine the extrusion scheme and optimize the granulator structural parameters.

The stresses induced in reinforced plastic matrix pipes by saddle supports

1982 ◽  
Vol 17 (3) ◽  
pp. 147-155 ◽  
Author(s):  
C B Greatorex ◽  
A S Tooth
Keyword(s):  
Analytical Approach ◽  
Shell Theory ◽  
Experimental Results ◽  
Pipe Material ◽  
Design Features ◽  
Analytical Results ◽  
Reinforced Plastic ◽  
Pipe Radius ◽  
Series Of Experiments ◽  
Plastic Matrix

The results of a series of experiments conducted on reinforced plastic matrix pipes show how the peak stresses, occurring in the saddle support region, can be reduced in magnitude by certain design features. Two methods are found of value: (1) to use a flexible medium, such as PVC or rubber, between the saddle and pipe, and (2) to support the pipe on a saddle with a radius greater than the pipe radius. The experimental results are compared with an analytical approach using shell theory making the assumption that the pipe material is isotropic. The agreement between the experimental and analytical results is promising.

Experimental Investigation on the Residual Stresses Induced by a Plastic Forming Process

2010 ◽  
Vol 452-453 ◽  
pp. 821-824 ◽  
Author(s):  
Giuseppe Lamanna ◽  
Luigi Grassia ◽  
Vascione Ascione
Keyword(s):  
Residual Stress ◽  
Stress State ◽  
Residual Stresses ◽  
Trial And Error ◽  
Forming Process ◽  
Cross Sectional ◽  
Residual Stress State ◽  
Stretch Bending ◽  
Bending Process ◽  
Plastic Forming

The extrusion of a space frame must be followed by forming operations of some kind to obtain the desired shape/curvature, for example a stretch bending process. Therefore, one has to face with problems as production tolerances and cross-sectional distortions of the curved product. In house experience combined with trial–and–error procedures have been traditionally used to cope with the said problems. Aircraft frames show significant residual stresses as a consequence of plastic forming processes. A great number of variables, such as initial frame length and/or final additional stretch, can influence the stress state of frames determining their life and efficiency under operating loading conditions. In the present paper, we refer about the experimental evaluations of the residual stress state of aircraft frames which have carried out taking into account different process parameters. The experimental results obtained and discussed show some interesting trends: they demonstrate that the residual stresses of the formed component can be controlled and reduced.

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