Research on the Blank Selection in the Power Spinning Process of Parts with Transverse Inner Rib

2007 ◽  
Vol 561-565 ◽  
pp. 885-888 ◽  
Author(s):  
Fei Ma ◽  
He Yang ◽  
Mei Zhan
Keyword(s):  
Cone Angle ◽  
High Strength ◽  
Forming Limit ◽  
Fe Model ◽  
Military Industry ◽  
Power Spinning ◽  
Forming Technology ◽  
Spinning Process ◽  
Increasing Demand ◽  
Half Cone

The advent of high-strength and high-precision thin-walled parts with inner ribs adapts to the increasing demand of aerospace industry, astronautics industry, military industry, and so on. For a new metal forming technology, how to determine the reasonable blank is a key problem required solved firstly in the research of power spinning process of parts with transverse inner rib. In this paper, based on the platform ABAQUS/Explicit, a reasonable 3D FE model for power spinning of parts with transverse inner rib has been established, the power spinning process of parts with transverse inner rib has been simulated under conditions of four typical blanks and the reasonable blanks for different forming processes have been obtained. The results show the following:(1) Blank with equal half-cone angle is the best selection to deform workpiece with proper height rib; (2) while for the workpiece with excessive height rib which exceed the forming limit, blank with rib is the exclusive selection, although it is difficult to be prepared comparing with non-rib blank.

Forming Limit Extension of High-Strength Steels in Bending Processes

2014 ◽  
Vol 611-612 ◽  
pp. 1110-1115 ◽  
Author(s):  
Mohamed El Budamusi ◽  
Andres Weinrich ◽  
Chrstioph Becker ◽  
Sami Chatti ◽  
A. Erman Tekkaya
Keyword(s):  
Hydrostatic Pressure ◽  
Metal Forming ◽  
Fem Simulation ◽  
High Strength Steels ◽  
High Strength ◽  
Forming Limit ◽  
Forming Limits ◽  
Air Bending ◽  
Forming Technology ◽  
Bending Process

Bending is a commonly used forming technology in metal forming. The occurring springback and low forming limits of high-strength steels especially during air bending are the main disadvantages. In this paper, the conventional air bending process is applied with a hydrostatic pressure in the bending zone. This was done using an elastomer tool. The advantage of this method is that the flexibility of air bending is maintained by reducing the springback while the forming limits are extended. Furthermore, different geometries for the elastomer tool were investigated by means of a FEM simulation. The investigation leads to a reduction of the process forces by minimizing the springback and to an extension of the forming limits.

Basic Investigations of Non-Pre-Punched Joining by Forming of Aluminium Alloy and High Strength Steel with Shear-Clinching Technology

2014 ◽  
Vol 611-612 ◽  
pp. 1413-1420 ◽  
Author(s):  
Marion Merklein ◽  
Gerson Meschut ◽  
Martin Müller ◽  
Réjane Hörhold
Keyword(s):  
Impact Load ◽  
Lightweight Design ◽  
High Strength Steels ◽  
High Strength ◽  
Joining By Forming ◽  
Forming Technology ◽  
Process Reliability ◽  
Mechanical Clinching ◽  
Increasing Demand ◽  
The One

Facing a decreasing amount of resources on the one hand and an increasing demand for comfort on the other, more and more attention is being paid to sustainability and care for the environment. Particularly in the automotive sector, lightweight design principles continue to prosper rapidly. As a result, adjusted materials for different applications were developed. Due to the formation of intermetallic phases, most multi-material mixes cannot be welded and require adapted joining technologies. Mechanical joining technologies such as self-piercing riveting and mechanical clinching have proven effective methods of joining lightweight materials like aluminium and ductile steels. New high-strength steels are increasingly used in crash-sections, where limited deformation under impact load is required. These hot stamped steels have a very low elongation at break and therefore a low formability. Currently there is no joining by forming technology without pre-punching available using these grades of steels on die-side. The newly developed shear-clinching process is one possible method of joining this kind of material without additional elements. The fundamental idea of shear-clinching is a single-stage process in which pre-punching of the die-side material is performed by indirect shear-cutting and subsequent forming of the upper layer into this hole. This would immensely enlarge the application segment of mechanical clinching even if hot stamped steels are positioned on die-side. Fundamental studies are required to ensure process reliability and it is necessary to break down the joining process into fragments, like pre-punching and clinching with pre-punched sheet, and superpose them to form the combined procedure shear-clinching. This paper presents a detailed investigation of the sub-process clinching with pre-hole.

Study on the Metal Flow in Power Spinning Process of Parts with Transverse Inner Rib

2011 ◽  
Vol 189-193 ◽  
pp. 2970-2975 ◽  
Author(s):  
Fei Ma ◽  
He Yang ◽  
Qiang Deng ◽  
Mei Zhan ◽  
Li Jin Hu
Keyword(s):  
Deformation Zone ◽  
Metal Flow ◽  
Plastic Deformation Zone ◽  
Fe Model ◽  
Forming Process ◽  
Precise Control ◽  
Power Spinning ◽  
Forming Defect ◽  
Spinning Process ◽  
Forming Defects

In this paper, by using a practical 3D FE model, one power spinning process of parts with transverse inner rib has been simulated. The stress and strain fields have been obtained and the features of metal flow in plastic deformation zone have been discussed thoroughly. Then, the main forming defects and their origins have been explored based on the study of the metal flow, shown as follows; (1) during the non-rib process, the main forming defect is the wall fracture in finished deformation zone. The origin of this forming defect is the excessive metal flow in thickness direction ahead of the forming roller. (2) in the rib-forming process, the main forming defect is the undesired inner rib. The origin of this forming defect is the excessive metal flow in hoop direction during the former non-rib process. (3) the features of the metal flow during flange part process are almost the same as those in the non-rib process. The achievements of this study can thoroughly reveal the deformation mechanism and provide an important basis for the optimization of the process parameters and the precise control of the power spinning process of parts with transverse inner rib.

Influence of Temperature and Deformation on Phase Transformation and Vickers Hardness in Tailored Tempering Process: Numerical and Experimental Verifications

2014 ◽  
Vol 136 (5) ◽  
Author(s):  
B. T. Tang ◽  
Q. L. Wang ◽  
S. Bruschi ◽  
A. Ghiotti ◽  
P. F. Bariani
Keyword(s):  
Vickers Hardness ◽  
Hot Stamping ◽  
High Strength Steels ◽  
High Strength ◽  
Fe Model ◽  
Forming Technology ◽  
Water Recirculation ◽  
Die Temperature ◽  
Ultra High Strength Steels ◽  
Good Agreement

Hot stamping of quenchenable ultra high strength steels currently represents a promising forming technology for the manufacturing of safety and crash relevant parts. For some applications, such as B-pillars which may undergo impact loading, it may be desirable to create regions of the part with softer and more ductile microstructure. In the article, a laboratory-scale hot stamped U-channel was produced with segmented die, which was heated by cartridge heaters and cooled by chilled water recirculation independently. It can be concluded that in order to satisfy tailored mechanical properties by introducing regions, which have an increased elongation for improved energy absorption, the minimum die temperature should be no less than 450 °C. Optical micrographs were used to verify the microstructure of the as-quenched phases with respect to the heated die temperatures. For the cooled die region, the microstructure was predominantly martensite for all the die temperatures interested. With the increase of heated die temperature, there was a decrease of Vickers hardness in the heated region due to the increasing volume fractions of bainite. The finite element (FE) model was developed to capture the overall hardness trends that were observed in the experiments. The trends between the simulations and experiments were very similar, with acceptable differences in the magnitude of Vickers hardness. The transition widths were measured and simulated and there was a quite good agreement between experiment and simulation with almost the same value of 10 mm by taking heat conduction into account.

Spinning Process of D406A Ultra-High Strength Steel

2021 ◽  
Vol 1035 ◽  
pp. 410-417
Author(s):  
De Gui Liu ◽  
Fu Long Chen ◽  
Hai Bao Wu ◽  
Ji Zhen Li ◽  
Jian Fei Wang
Keyword(s):  
Heat Treatment ◽  
High Strength Steel ◽  
High Strength ◽  
Ferrite Matrix ◽  
Forming Limit ◽  
Martensitic Structure ◽  
Ultra High Strength Steel ◽  
Limit Test ◽  
Spinning Process ◽  
Thinning Rate

D406A steel is a medium-carbon low-alloy steel, which has excellent comprehensive mechanical properties. It is widely used in the production of missiles and rocket barrels. In this paper, the spinning forming limit test and the intermediate heat treatment process of ultra-high-strength steel were used to explore the effect of spinning process and heat treatment on the properties of spinning parts. The research results showed that the reduction amount of the material made the material thinning rate approach the limit thinning rate. The final blank wall thickness was reduced from 15 mm to 3.0 mm when the cracking occurred. It was calculated that the material's power spinning limit thinning rate was 80%. The ferrite matrix after spinning showed a streamline distribution characteristic perpendicular to the thinning direction, and the precipitated carbides were uniformly distributed on the surface of the matrix, which had the characteristics of deformation and extension along the streamline. After the heat treatment, the structure of the spinning parts changed continuously. When the structure was quenched and tempered, the martensitic structure can be obtained, and the tempered martensitic structure was smaller. Furthermore a test piece for ultra-high-strength steel spinning technology has been developed, and the solutions discussed for flanging defects in the actual spinning process, and test data for the actual production of ultra-high-strength steel spinning parts accumulated.

Numerical Simulation of Stagger Spinning for D406A High-Strength Steel

2019 ◽  
Vol 944 ◽  
pp. 778-787
Author(s):  
Kai Di Li ◽  
De Gui Liu ◽  
Jin Shan Li ◽  
Bin Tang ◽  
Hong Chao Kou
Keyword(s):  
Feed Rate ◽  
Rotational Speed ◽  
Process Analysis ◽  
Dimensional Accuracy ◽  
High Strength ◽  
Internal Diameter ◽  
Fe Model ◽  
Software Environment ◽  
Power Requirement ◽  
Spinning Process

Metal spinning process is widely used because of its low power requirement to producing complex symmetry components. In this paper, a modified 3D finite element(3D-FE) model is developed under the FE software environment based on characteristics of stagger spinning process. Analysis of the multi-pass spinning deformation mechanism and the effects of spinning parameters on spinning deformation is carried out. The results show that, large internal diameter of tube blank and low dimensional accuracy are caused by too little feed rate of spinning roller, especially for thin-walled tube. But if the feed rate is larger than 60mm/min, large spinning forces and instability appear. Strain rate and forming instability increase with the increase of rotational speed of mandrels, on the other hand, more obvious friction leads to bigger strain of surface of tube blank. With the radius of corner of spinning roller getting 13mm, the extensive overlaps lead to the improvement of spinning efficiency, while low forming quality accompanied by the large spinning forces occurs. Cutting phenomena leads to worse surface quality even tends to crack with the radius of corner of spinning roller being smaller than 8mm. An ideal combination of process parameters is obtained: the roller feed rate is 50mm/min, the rotational speed of mandrel is 40rad/min, the radius of corner of spinning roller is 10mm.

The Microstructure and Formability Study on DP Steel of Lightweight Automobile

2011 ◽  
Vol 704-705 ◽  
pp. 1465-1472
Author(s):  
Jin Wu ◽  
Da Sen Bi ◽  
Liang Chu ◽  
Jian Zhang ◽  
Yun Tao Li
Keyword(s):  
Mechanical Property ◽  
Work Hardening ◽  
High Strength Steel ◽  
High Strength ◽  
Mathematic Model ◽  
Theoretical Research ◽  
Forming Limit ◽  
Strain Hardening Exponent ◽  
Dp Steel ◽  
Better Than

Dual phase (DP) steel is a high strength steel for auto-panel. In this paper, mechanical property, forming ability, baked-hardening and work hardening properties of high strength steel DP450 are studied by experiments, and compared with those of steel MS6000.And theoretical research on predicting the forming limit of steel DP450 by the NADDRG model. The established mathematic model for relativity is of practical usefulness. Experimental results reveal that the yield strength of steel DP450 is about 7.2% lower than the MS6000,and the break strength increases by 18.9%,while the elongation increases by 19%.The strain hardening exponent of steel DP450 are superior to those of MS6000.The results show that mechanical property of high strength steel DP450 is better than that of MS6000,while forming ability of DP450 is not lower than that of MS6000.And baked-hardening and work hardening properties of steel DP450 are better than those of MS6000.The steel sheet DP450 owned a good forming ability.

Enhancement of the tensile shear strength for joining low-ductility aluminium to high-strength steel by using electrically-assisted mechanical clinching (EAMC)

2021 ◽  
pp. 095440542199565
Author(s):  
Abozar Barimani-Varandi ◽  
Abdolhossein Jalali Aghchai
Keyword(s):  
Shear Strength ◽  
High Strength Steel ◽  
High Strength ◽  
Fe Model ◽  
Tensile Shear Strength ◽  
Tensile Shear ◽  
Electroplastic Effect ◽  
Fracture Displacement ◽  
Electrically Assisted ◽  
Mechanical Clinching

The present work studied the enhancement of the tensile shear strength for joining AA6061-T6 aluminium to galvanized DP590 steel via electrically-assisted mechanical clinching (EAMC) using an integrated 2D FE model. To defeat the difficulties of joining low-ductility aluminium alloy to high-strength steel, the electroplastic effect obtained from the electrically-assisted process was applied to enhance the clinch-ability. For this purpose, the results of experiments performed by the chamfering punches with and without electrically-assisted pre-heating were compared. Joint cross-section, failure load, failure mode, fracture displacement, material flow, and failure mechanism were assessed in order to study the failure behaviour. The results showed that the joints clinched at the EAMC condition failed with the dominant dimpled mechanism observed on the fracture surface of AA6061 side, achieved from the athermal effect of the electroplasticity. Besides, these joints were strengthened 32% with a much more fracture displacement around 20% compared with non-electrically-assisted pre-heating.

Coupled Thermo-Mechanical FEA of Three-Roll Cross Rolling Process for Rings with Small-Hole and Deep Groove

2012 ◽  
Vol 560-561 ◽  
pp. 846-852 ◽  
Author(s):  
Qi Ma ◽  
Lin Hua ◽  
Dong Sheng Qian
Keyword(s):  
Rolling Process ◽  
Small Hole ◽  
Fe Model ◽  
Forming Process ◽  
Software Environment ◽  
Cross Rolling ◽  
Design And Optimization ◽  
Forming Technology ◽  
Deep Groove ◽  
Plastic Forming

Ring parts with small-hole and deep groove such as duplicate gear and double-side flange, are widely used in various engineering machineries. Three-roll cross rolling (TRCR) is a new advanced plastic forming technology for the processing of rings with small-hole and deep groove. In this paper, a 3D coupled thermo-mechanical FE model for TRCR of ring with small-hole and deep groove is established under ABAQUS software environment. By simulation and analysis, the evolution and distribution laws of strain and temperature in the forming process are revealed, and the effects of the key process parameters on the deformation uniformity are explored. The results provide valuable guideline for the technological parameter design and optimization.

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