A New Method of Flanges Extrusion in Hollow Products – Analysis of the Limiting Phenomena

Winiarski, Grzegorz; Bulzak, Tomasz; Wójcik, Łukasz; Szala, Mirosław

doi:10.12913/22998624/125508

Cited by 5 publications

(4 citation statements)

References 13 publications

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“…The forming process is a combination of extrusion and upsetting. More details regarding the evolution of the idea of elaborated metal forming technology are presented in previous papers [30,[32][33][34]. The current study physically modeled the metal forming process in laboratory conditions using a 1:2.5 scale of die tools.…”

Section: Forging Of the Hollow Steel Component With An Outer Flangementioning

confidence: 99%

Microstructure and Hardness of Cold Forged 42CrMo4 Steel Hollow Component with the Outer Flange

Szala¹,

Winiarski²,

Bulzak³

et al. 2022

Adv. Sci. Technol. Res. J.

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For decades, steel has been a crucial structural material. Mainly low-alloy steel grade 42CrMo4 is utilized for manufacturing forgings. This paper investigates the microstructure and hardness development of the 42CrMo4 steel hollow component with an outer flange. The component has been formed via cold forging in combination with extrusion and upsetting technologies. Prior to forming, the workpiece was annealed to obtain hardness at the level of 181±9 HV0.3. The FEM analysis reveals the areas that undergo higher stress and strain. The flow lines macrostructure and microstructure of hollow parts were investigated using light optical microscopy (LOM) and scanning electron microscopy (SEM) equipped with EDS. Vickers hardness allows identifying the work hardening of the crucial element areas. The microstructure consists of ferrite matrix and semispherical carbides. Laboratory studies confirm appropriate flow lines arrangement, which corresponds well to those shown by FEM computer simulations. The highest hardness at the level of 293±7 HV0.3 was identified in the flange area, where the material shows a higher distribution of effective strain revealed by FEM. Cold metal forming results in work-hardening of the steel. The work hardening ranges up to 1.62 of the initial 42CrMo4 steel hardness. The metal forming process did not affect the microstructural uniformity of the flanged hollow part. The final outer flange component presents high quality and is free from plastic deformation nonuniformities.

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Section: Forging Of the Hollow Steel Component With An Outer Flangementioning

confidence: 99%

Microstructure and Hardness of Cold Forged 42CrMo4 Steel Hollow Component with the Outer Flange

Szala¹,

Winiarski²,

Bulzak³

et al. 2022

Adv. Sci. Technol. Res. J.

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“…In closed-die extrusion, the flange height could be several times greater than the workpiece wall thickness, which allowed for multi-step flange forming [24,25]. In semi-open die extrusion, the achievable flange height was constrained by a potential loss of workpiece/mandrel contact in the zone outside the die impression as well as flank inclination [26,27].…”

Section: Introductionmentioning

confidence: 99%

Analysis of a New Process for Forming Two Flanges Simultaneously in a Hollow Part by Extrusion with Two Moving Dies

Winiarski,

Gontarz,

Skrzat

et al. 2024

Metals

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This paper presents a new method for forming flanges in hollow parts. The process consists of an extrusion with two dies that move in an opposite direction to that of the punches. This particular kinematics of the tools makes it possible to form two flanges simultaneously in a single tool pass. The proposed method was investigated using a tube made of steel 42CrMo4. It was assumed that the extrusion would be conducted as a cold forming process at ambient temperature. Different diameters and heights of the impression made in the top and bottom dies were used. It was demonstrated that the main failure mode of the proposed technique was an unintended increase in the inside the diameter of the workpiece in the flange zone. The results showed that the above parameters had a key impact on the achievable maximum flange diameters and heights.

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“…The method is based on extrusion with the use of a moveable sleeve, and parts are formed in a semi-open die cavity. The method is dedicated to manufacturing forged parts directly from hollow [56] or solid billets, or to further processing of stepped forged parts. During extrusion there is a simultaneous increase in the outside diameter and wall thickness of a workpiece region being formed.…”

Section: Introductionmentioning

confidence: 99%

Theoretical and Experimental Study on the Effect of Selected Parameters in a New Method of Extrusion with a Movable Sleeve

Winiarski

2022

Materials

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This paper presents a new method for forming hollow flanged products. The method involves extrusion with the use of a sleeve moving in the opposite direction to that of the punch. A tube with a constant hole diameter and two different outside diameters, made of aluminum alloy EN AW 6060 was used as a material. Numerical calculations were performed using Deform 2D/3D. Experiments were conducted on the PYE 160SS hydraulic press equipped with a specially designed device in which the punch is driven by the press slide while the moveable sleeve is driven by two hydraulic servomotors. Both numerical simulations and experiments were conducted under cold forming conditions. The aim of this study was to determine the effect of selected parameters (flange diameter, height of the cavity in the moveable sleeve, and the chamfer angle between the regions with different outside diameters on the workpiece and in the moveable sleeve cavity) on the stability of the extrusion process. Results were then used to undertake detailed comparative analyses of underfill, flange heights, and flange flank inclination angles. Findings of the analyses served as a basis for drawing conclusions regarding the effect of the analyzed parameters on the investigated extrusion process.

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A New Method of Flanges Extrusion in Hollow Products – Analysis of the Limiting Phenomena

Cited by 5 publications

References 13 publications

Microstructure and Hardness of Cold Forged 42CrMo4 Steel Hollow Component with the Outer Flange

Microstructure and Hardness of Cold Forged 42CrMo4 Steel Hollow Component with the Outer Flange

Analysis of a New Process for Forming Two Flanges Simultaneously in a Hollow Part by Extrusion with Two Moving Dies

Theoretical and Experimental Study on the Effect of Selected Parameters in a New Method of Extrusion with a Movable Sleeve

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