Determination of the forming tool load in plastic shaping of a round tube into a square tubular section

Bayoumi, Laila S.; Attia, Ahmed S.

doi:10.1016/j.jmatprotec.2008.04.047

Cited by 21 publications

(8 citation statements)

References 7 publications

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“…In another study, 18 they generalized this method for the multistage forming process to produce polygonal cross-sectional thick single-layer tubes by means of a roll forming rig with flat rolls. Bayoumi and Attia 19 analyzed the plastic forming of a circular tube into a square one through four idle flat rolls to determine drawing force and the tool load using experimental observations, analytical expressions and the ﬁnite element simulation. Tajyar and Abrinia 20 examined analytically the reshaping of circular single layer tubes between four flat rolls in different stages using ﬁnite element simulation.…”

Section: Introductionmentioning

confidence: 99%

Experimental analysis of bonding strength in shape rolling of Al–Cu bimetallic circular pipes into square tubes

Tajyar

Masoumi

2016

Proceedings of the Institution of Mechanical Engineers, Part C:

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In the present research, the intermetallic layer situation and bond strength of square tubes produced by shape rolling of Al–Cu bimetallic pipes has been investigated. The explosive welding process was used for the production of bimetallic circular pipes. The macro- and microscopic features of explosive-welded pipes and shape-rolled specimens at various stages were experimentally measured by using shear and hardness testing and optical metallography. Moreover, scanning electron microscopy was used for fractography of the fracture surfaces after the last stage of forming. The experimental results showed that the shear strength variation is dependent on the intermetallic layer thickness and its continuity. Also, continuity in Al–Cu interfaces that have a thick intermetallic layer intensifies the microcrack propagation, while due to discontinuity in the thin intermetallic layer, the retardation of catastrophic crack propagation was observed in the early passes of the shape-rolling process. However, the results of the present study showed that as the passes proceed in the rolling process, the crack propagation phenomenon, which is the cause of a decrease in shear strength, is expected.

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Section: Introductionmentioning

confidence: 99%

Experimental analysis of bonding strength in shape rolling of Al–Cu bimetallic circular pipes into square tubes

Tajyar

Masoumi

2016

Proceedings of the Institution of Mechanical Engineers, Part C:

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“…The tubes with polygonal shapes outperform round ones while joining and assembly of structural components especially in fabrication of lightweight frames and building with coachwork shape. 1 Fabrication of polygonal metal products from round tube is a plastic metal forming process that various researches attempted to investigate its performance by numerical simulation, theoretical analysis, and experimental works. In a research by Bayoumi et al, 2 they developed a theoretical model for prediction of drawing force and roller load by variation of section shape, friction coefficient in the roll-sheet interface, roll radius, and wall thickness.…”

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Optimization of tube drawing process through FE analysis, intelligent computation, and experimental verification

Jafari

Hosseinzadeh

Elyasi

2016

Proceedings of the Institution of Mechanical Engineers, Part E:

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In present study, an attempt based on a hybrid approach was made to find optimal tube drawing parameters combination (i.e., die semi-angle, friction coefficient, tube entrance velocity, deformation length, and primary tube diameter) achieving minimum forming force, minimum dimensional error along with maximum thickness in longitudinal and circumferential directions. In order to form a design matrix, Taguchi L27 design was used and required data were derived from finite element model of the process. Adaptive neuro-fuzzy inference system (ANFIS) was then used to correlate process inputs to and responses aforementioned response outputs. Prediction accuracy of created ANFIS models was further checked by FE simulation and experimental testing data. Finally, the models were integrated to form objective function that was optimized by teaching-learning-based optimization (TLBO) algorithm. To check the adequacy of optimization, a finite element run and an experiment were carried out by obtained optimal parameter setting and the results were compared. The findings indicated that that the proposed methodology, that is, FEA-ANFIS-TLBO has superiority in identifying the optimal results.

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“…Abrinia and Farahmand 22 used a new solution based on upper-bound method to solve three-dimensional (3D) problem of reshaping of thick square tube from a round one. Bayoumi and Attia 23 determined the forming tool load in plastic shaping of a round tube into a square tubular section analytically and also numerically by applying finite element simulation. Yuan et al 24 investigated filling behavior of a transition corner by theoretical analysis and also, with experimental and finite element method for a rectangular column during the hydroforming process.…”

Section: Introductionmentioning

confidence: 99%

Theoretical and experimental investigation of shaping process of circular metal tubes into triangular columns by the elastoforming method

Niknejad

Amirhosseini

Setoudeh

2016

Proceedings of the Institution of Mechanical Engineers, Part B:

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In this article, a new manufacturing method is introduced to shape circular tubes into columns with triangular cross-section by the elastoforming process. Also, a theoretical analysis is performed to derive a theoretical formula for predicting total dissipated energy that is required for the forming process. For this purpose, V-shape dies with different angles are designed and some aluminum and brazen tubes with different characteristics are prepared. The circular tubes in the empty and filled conditions are compressed between a rigid V-shape die and a flat punch, and during the plastic deformation under the lateral loading, the tubes are shaped into the triangular sections. Considering different tube lengths, outer diameters and wall thicknesses, the specimens are categorized. Also, some of the samples are filled by cylindrical polyethylene Teflon with different thicknesses to investigate the effects of Teflon-filler on the shaping process of the triangular columns. The experiments show that using the cylindrical Teflon-filler, deformation mode of the triangular tubes improves, significantly. In addition, experimental observations of the deformation modes illustrate that there is an optimum value for wall thickness of cylindrical Teflon-filler and the tubes with the optimum Teflon-filler forms close to desirable triangular shape. The results show that by increasing tube wall thickness, probability of crack initiation and fracture reduces. Furthermore, comparison of estimations by the presented theory and the corresponding experimental measurements show an acceptable agreement, in both of empty and filled conditions.

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Determination of the forming tool load in plastic shaping of a round tube into a square tubular section

Cited by 21 publications

References 7 publications

Experimental analysis of bonding strength in shape rolling of Al–Cu bimetallic circular pipes into square tubes

Experimental analysis of bonding strength in shape rolling of Al–Cu bimetallic circular pipes into square tubes

Optimization of tube drawing process through FE analysis, intelligent computation, and experimental verification

Theoretical and experimental investigation of shaping process of circular metal tubes into triangular columns by the elastoforming method

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