Product Geometry for Process Parameter during Rotary Swaging Process as Chipless Forming Process

2007 ◽  
Vol 544-545 ◽  
pp. 439-442
Author(s):  
Seong Joo Lim ◽  
Ho Joon Choi ◽  
Duk Jae Yoon ◽  
Ha Guk Jeong ◽  
C.H. Lee
Keyword(s):  
Process Parameters ◽  
Metal Flow ◽  
Dimensional Accuracy ◽  
Outer Diameter ◽  
Important Process ◽  
Percent Reduction ◽  
Forming Process ◽  
Cross Sectional ◽  
Rotary Swaging ◽  
Available Information

This study deals with the dimensional accuracy of outer diameter and geometrical workability in rotary swaged product for various process parameters such as percent reduction in outer diameter and the ratio of thickness to outer diameter of a tube. It is generally known that greater cold strengthening is achieved by rotary swaging process rather than by conventional process such as rolling with respect to the same reduction of cross-sectional area. Percent reduction in the diameter and the ratio are considered and selected as important process parameters because of playing a key role during rotary swaging process. In case of tube under rotary swaging process the ratios have influence on geometrically proper workability without defect for different percent reductions in the diameter. In addition the change of metal flow of workpiece under the swaging process is microscopically and globally observed to analyze the reason why dimensional accuracy of the outer diameter of final product is improved after the rotary swaging process. This work might provide available information for the optimum rotary swaging process.

Numerical Simulation on the Laser Bending of Thin Wall Tubes

2011 ◽  
Vol 460-461 ◽  
pp. 798-801 ◽  
Author(s):  
Nan Hai Hao ◽  
Yu Ling Gai
Keyword(s):  
Process Parameters ◽  
Three Dimensional ◽  
Mechanical Analysis ◽  
Outer Diameter ◽  
Thin Wall ◽  
Laser Bending ◽  
Cross Sectional ◽  
Bending Process ◽  
Mechanical Bending ◽  
The Cost

Laser tube bending is a spring-back-free noncontact forming method that has received considerable attention in recent years. Compared to mechanical bending, no hard tooling, dies, or external force is used in laser bending, thus the cost is greatly reduced for small-batch production and prototyping. Some quality issues, such as cross sectional distortion and intrados protrusion exist in laser bending and have growing tendency when the tube’s wall being thinner. This paper investigates the effects of process parameters on the deformation of thin wall tube through numerical simulations and experiments. The dimensions of the tube analyzed are 32 mm in outer diameter and 0.48mm in wall thickness. A three-dimensional transient thermo-mechanical analysis using the finite element method is carried out to simulate the laser bending process with some results validated by experiments. The effects of process parameters on the deformation of thin wall tubes are discussed in detail.

Dimensional Characteristics of Products Using Rotary Swaging Machine with Four-Dies

2007 ◽  
Vol 124-126 ◽  
pp. 1645-1648 ◽  
Author(s):  
Seong Joo Lim ◽  
Ho Joon Choi ◽  
Kyoung Hoan Na ◽  
C.H. Lee
Keyword(s):  
Surface Roughness ◽  
Outer Diameter ◽  
Process Variables ◽  
Dimensional Precision ◽  
Rotary Swaging ◽  
A Value ◽  
Dimensional Deviation ◽  
Product Defect ◽  
Available Information

Experiments under a cold rotary swaging process have been conducted to investigate the dimensional characteristics of the swaged tube and solid bar for obtaining proper product of desirable quality. Dimensional characteristics are expressed in terms of dimensional deviation and surface roughness of swaged product through the rotary swaging process. The process variables such as forming speed and percent reduction of outer diameter of the product are considered and selected because of playing a key role in the rotary swaging process. Furthermore the developed rotary swaging machine with four-split dies, named as KRSM25, is used in the swaged experiment. Based on the experimental results, it is observed that the process variables affect the quality of swaged product such as dimensional precision, surface roughness of the product. Defect could be found to occur at a value of more than 2.0 mm/rev in forming speed. The dimensional precision of swaged product depends on the percentage reduction of outer diameter and forming speed. The work presented in this paper might be used for available information in the design of the optimum rotary swaging process.

Rheological and printable behavior of resin – class materials for 3D printing applications

2019 ◽  
Vol 25 (5) ◽  
pp. 801-808
Author(s):  
Jianzhong Shang ◽  
Xin Li ◽  
Zhuo Wang ◽  
Rong Wang ◽  
Hong Zhu
Keyword(s):  
Process Parameters ◽  
Cross Sections ◽  
Rheological Behavior ◽  
Dimensional Accuracy ◽  
Cross Sectional ◽  
Content Type ◽  
Nozzle Height ◽  
Uniform Wall ◽  
The Cross ◽  
Printing Parameters

Purpose This study aims to investigate rheological and extrusion behavior of thermosetting epoxy resins, which to find the universal property and printing parameters for extrusion-based rapid prototyping applications. Design/methodology/approach The thickener proportion greatly influences its viscosity and rheological behavior and therefore plays an important role in the shape of the cross-section of the extrudate. Findings A pseudoplastic (shear-thinning) is a basic requirement for obtaining extruded lines with plump cross-sections. In addition to the effects of the rheological behavior of the composite, shape maintenance and its wettability on the substrate, the cross-sectional geometry of the extrudate is also strongly affected by printing process parameters including the extrusion nozzle height, nozzle moving speed, extrusion rate and critical nozzle height. Proper combinations of these process parameters are necessary to obtain single-line extrudates with plump cross-sections and 3-D objects with dimensional accuracy, uniform wall thickness, good wall uprightness and no wall slumping. Formulas and procedures for determining these extrusion parameters are proposed and demonstrated in experiments. Originality/value The results obtained have been explained in terms of the interactions among the rheological properties of the composite, the shear rate imposed on the composite during extrusion, the wettability of the composite on the substrate and the shape maintenance of the composite during extrusion.

Sensitivity Analysis of Process Parameters in the Drawing and Ironing Processes

2013 ◽  
Vol 554-557 ◽  
pp. 2256-2265 ◽  
Author(s):  
Vasco M. Simões ◽  
Jeremy Coër ◽  
Hervé Laurent ◽  
M.C. Oliveira ◽  
J. Luís Alves ◽  
...  
Keyword(s):  
Process Parameters ◽  
Deep Drawing ◽  
Thickness Distribution ◽  
Experimental Tests ◽  
Contact Forces ◽  
Outer Diameter ◽  
Forming Process ◽  
Punch Force ◽  
Inner Radius ◽  
Cylindrical Cup

Deep drawing is one of the most important operations used in sheet metal forming. Within this, forming of cylindrical cup is one of the most widely studied deep drawing processes since it allows analysing the effect of different process parameters in phenomena such as earing, springback and ironing. In fact, during the deep drawing of a cylindrical cup the blank thickness gradually increases as the blank outer diameter is reduced to the die inner diameter, resulting in a thickness increase from a point near the bottom radius until the maximum value at the top of the cup. Therefore, if the gap between the punch and the die is not sufficiently large to allow the blank material to flow, ironing of the cup wall will occur. The ironing process typically imposes high contact forces, normal to the surface of the punch and the die, which can lead to the occurrence of galling, particularly for aluminium alloys. In this work an experimental device, adopted in previous studies, was used to analyse the influence of the lubricant conditions in the deep drawing of a cylindrical cup. The study considers an AA5754-O aluminium alloy blank with a diameter of 60 mm, which is fully deep drawn with a 33 mm diameter punch. Due to the forming conditions, the cup is deep drawn and ironing of the cup wall also occurs. The experimental tests were performed considering different amounts of lubricant in the blank surfaces in the contact with the die and with the blank-holder in order to better understand the influence of these tools on the process. The experimental study was complemented with numerical simulations, exploring the conditions induced by the ironing operation, quite challenging for the numerical simulation of the process using the finite element method. Besides the influence of the contact with friction conditions in the forming process (i.e. punch force evolution, thickness distribution along the cup wall and contact pressure), the influence of the die shoulder and inner radius were also analysed.

Influence of the Tool Clearances on the Dimensional Accuracy of Mini Drawn Parts

2014 ◽  
Vol 1036 ◽  
pp. 309-313
Author(s):  
Gheorghe Brabie ◽  
Bogdan Chirita ◽  
Elena Costache ◽  
Robert Stefanut Teaca
Keyword(s):  
Process Parameters ◽  
Deep Drawing ◽  
Dimensional Accuracy ◽  
Thin Sheets ◽  
Forming Process ◽  
Cold Forming ◽  
Small Thickness ◽  
Theoretical Profile ◽  
Small Parts

The mini deep drawing is a cold forming process applied in order to realize small parts having dimensions smaller than 20 mm. In the case of such process the small thickness of sheet and the small dimensions of parts are the most important factors that influence the process parameters and can affect the accuracy and quality of the produced mini - parts. A proper clearance between the working tools components is also a very important factor that can permit to obtain mini drawn parts in accordance with their theoretical profile. The present paper analyses the results of investigations made by experiment and simulation concerning the influence of tool clearances values on the accuracy of dimensions in the case of mini scale cylindrical drawn cups made from thin sheets. The deviations from the cups theoretical profile (wall inclination, variation of part diameter) that can occur during deep drawing of such sheets were especially analyzed in the paper.

scholarly journals Design of Multi-Stage Roll Die Forming Process for Drum Clutch with Artificial Neural Network

Materials ◽  
2020 ◽  
Vol 14 (1) ◽  
pp. 69
Author(s):  
Jae-Hong Kim ◽  
Jae-Chang Ryu ◽  
Woo-Sik Jang ◽  
Joon-Hong Park ◽  
Young-Hoon Moon ◽  
...  
Keyword(s):  
Neural Network ◽  
Artificial Neural Network ◽  
Fe Simulation ◽  
Dimensional Accuracy ◽  
Outer Diameter ◽  
Forming Process ◽  
Multi Stage ◽  
Die Set ◽  
Artificial Neural ◽  
Die Forming

The multi-stage roll die forming (RDF) process is a plastic forming process that can manufacture a transmission part with a complex shape, such as a drum clutch, by using a die set with rotational rolls. However, it is difficult to satisfy dimensional accuracy because of spring-back and unfilling. The purpose of this study is to design a multi-stage RDF process for the manufacturing of a drum clutch to improve dimensional accuracy using an artificial neural network (ANN). Finite element (FE) simulation of the multi-stage RDF process is performed to predict the dimensional accuracy according to various clearances for each stage. Moreover, the ANN is used to determine the relationship between the clearance and dimensional accuracy of the drum clutch to reduce the number of FE simulation. The results of the FE simulation and ANN are used to determine the optimal clearance for each stage of the RDF process. Finally, the drum clutch is fabricated using the determined conditions. The experimental results are in good agreement with the results of FE simulation from the aspect of outer diameter, inner diameter, thickness of outer tooth, thickness of inner tooth, and face thickness of tooth.

Conventional Super Plastic Forming and Multi-attribute Optimization through VIKOR and ANOVA

2020 ◽  
Vol 12 (1) ◽  
Author(s):  
A. Thirugnanam ◽  
S.P. Sundar Singh Sivam ◽  
K. Saravanan ◽  
N. Harshavardhana ◽  
D. Kumaran
Keyword(s):  
Process Parameters ◽  
Automotive Industry ◽  
Complex Geometry ◽  
Metal Flow ◽  
Maximum Height ◽  
Forming Process ◽  
Super Plastic ◽  
Plastic Forming ◽  
Item Quality ◽  
Super Plastic Forming

Super plastic forming is a manufacturing process utilized in the automotive industry like vehicle structures to produce complex geometries of aluminium or magnesium alloy components which cannot be fabricated at room temperature. The technique has proven to be an efficient cost-worthy process in forming various lightweight components for aerospace and medical applications During the process, parameters such as die entry radius, pressure, temperature and material thickness at the sheet die interface greatly influence the metal flow and also depends on product quality. The aim of prsent work is to optimise the conventional super plastic forming process parameters for getting the better quality with proper dimensions of hemispherical cup out of AA2024 sheet. The sheet is placed in a die, which can have a simple to complex geometry depends on the final part to be produced. It is shaped into the hemispherical cup using compressed air. These input process parameters were varied and output parameters such as thickness, maximum height, diameter and minimum forming time of cup were studied and L9 Orthogonal array with a specific end goal to acquire the yield parameters influencing item quality, both VIKOR and ANOVA were assessed.

Effect of Process Parameters on Dimensional Accuracy of the Part in Hot Press Forming Process

2012 ◽  
Vol 189 ◽  
pp. 250-254
Author(s):  
An Long ◽  
Rui Ge ◽  
Hui Wang ◽  
Yin Chen
Keyword(s):  
Process Parameters ◽  
Dimensional Accuracy ◽  
Hot Press ◽  
Forming Process ◽  
Optical Scanner ◽  
Press Forming ◽  
Hot Press Forming ◽  
Actual Part

To research the problem of part’s dimensional accuracy error easily occurred in hot press forming, a B-Pillar on one domestic car was set as example, the dimensional of the actual part and its model diagram were compared by means of ATOS optical scanner. By recording the the process parameters used in practical production, the effect trend of three key process parameters on part’s dimensional accuracy was summarized, process parameters suitable for practical production were gained.

Deformation Characteristics in Radially Extruded Tubular Parts

2005 ◽  
Vol 475-479 ◽  
pp. 4203-4206 ◽  
Author(s):  
Hyoung Jin Choi ◽  
S.H. Kim ◽  
Beong Bok Hwang
Keyword(s):  
Metal Flow ◽  
Process Condition ◽  
Deformation Analysis ◽  
Deformation Pattern ◽  
Outer Diameter ◽  
Forming Process ◽  
Rigid Plastic ◽  
Design Data ◽  
Gap Height ◽  
Tubular Components

Radially extruded tubular components are adopted for the deformation analysis by rigid-plastic finite element method. FE Simulations were conducted to investigate the influence of different geometric parameters and process condition, such as the ratio between inner and outer diameter of tubular components, gap height, die corner radius and friction factor, on metal flow into radial direction. The results of the simulations are discussed in terms of separation length, defined as the length that the material flow is separated away from the die in gap height, and maximum force requirements for the radial forming process. Furthermore the pressure distributions exerted on the die-wall interfaces and deformation pattern was shown to obtain the features in producing sound radial extruded components. Finally some guidelines for basic design data in the radial extrusion process due to this simulation work might be drawn up.

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