Enhanced granular medium-based tube and hollow profile press hardening

Chen, Hui; Hess, Sigrid; Haeberle, Jan; Pitikaris, Sebastian; Born, Philip; Güner, Alper; Sperl, Matthias; Tekkaya, A. Erman

doi:10.1016/j.cirp.2016.04.010

Cited by 27 publications

(5 citation statements)

References 15 publications

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“…Both materials are shown in Figure 11. These granular media have already been successfully applied to a tube press hardening process by Chen et al [19].…”

Section: Methodsmentioning

confidence: 99%

Increasing the Lightweight Potential of Composite Cold Forging by Utilizing Magnesium and Granular Cores

Gitschel

Kolpak

Hering

et al. 2020

Metals

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In this paper a process sequence, that uses forward rod extrusion with cold forged C15 steel cup billets to produce lightweight shafts, is presented. The steel cup billets feature either a lightweight magnesium alloy core or a granular medium core that is removed after forming to obtain hollow shafts without the need of complex tools and highly loaded mandrels. It is shown that composite shafts featuring magnesium cores can be produced for a wide range of extrusion strains. Due to high hydrostic pressures in forward rod extrusion, the forming limit of magnesium at room temperature can be expanded. The observed bond strength between core and sheath is below the shear yield strength of utilized magnesium AZ31 alloy. Hollow shafts are successfully produced with the presented process route by utilizing zirconium oxide beads or quartz sand as a lost core. As the law of constant volume in metal forming is violated by compressible granular media, a simulation approach using a modified Drucker-Prager yield surface to model these materials is validated to provide a tool for efficient process design. Granular cores and magnesium alloy cores offer new possibilities in production of lightweight shafts by means of composite cold forging. Both process variants allow for higher weight savings than composite shafts based on aluminum cores.

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“…Both materials are shown in Figure 11. These granular media have already been successfully applied to a tube press hardening process by Chen et al [19].…”

Section: Methodsmentioning

confidence: 99%

Increasing the Lightweight Potential of Composite Cold Forging by Utilizing Magnesium and Granular Cores

Gitschel

Kolpak

Hering

et al. 2020

Metals

Self Cite

View full text Add to dashboard Cite

show abstract

“…air, nitrogen, argon). Smart fluids show promise but are in the early stages of development and carry a host of technical challenges and understanding required [116] and ceramic beads are not technically a fluid so hydrostatic pressure is not guaranteed and forces are transmitted through Bforce chains^ [117]. In addition, the medium can have wear issues as ceramic beads break down after use.…”

Section: Warm Hydroformingmentioning

confidence: 99%

A state of the art review of hydroforming technology

et al. 2019

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Hydroforming is a relatively new metal forming process with many advantages over traditional cold forming processes including the ability to create more complicated components with fewer operations. For certain geometries, hydroforming technology permits the creation of parts that are lighter weight, have stiffer properties, are cheaper to produce and can be manufactured from fewer blanks which produces less material waste. This paper provides a detailed survey of the hydroforming literature of both established and emerging processes in a single taxonomy. Recently reported innovations in hydroforming processes (which are incorporated in the taxonomy) are also detailed and classified in terms of “technology readiness level”. The paper concludes with a discussion on the future of hydroforming including the current state of the art techniques, the research directions, and the process advantages to make predictions about emerging hydroforming technologies.

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“…Rubber bulging is too dependent on rubber molds, and the limited durability of rubber molds can lead to unstable processing quality and the need to replace molds periodically, which increases production costs. The pipe granules medium flexible bulging process [9] (Solid Granules Medium Forming Technology, SGMF) as a modern plastic processing technology, is to pipe as a billet, the use of solid non-metallic particles instead of the traditional rigid convex die as a pressure transfer medium, by applying the axial force to the pipe inside the filler to the pipe billet molded into the desired shape of an advanced manufacturing technology [10][11][12][13]. Granular media have high pressure-bearing capacity [14], with certain fluidity and filling properties in high-pressure environments; the granular media forming process has good dimensional control and shape reproducibility [15], with low equipment requirements, maximizing material savings and reducing environmental impact [16][17].…”

Section: Introductionmentioning

confidence: 99%

“…Fig 13. Geometric deviation of egg-shaped shell expanders from prefabricated blanks at different pusher head heights…”

mentioning

confidence: 99%

Influence of unidirectional loading pusher head structure on the deformation law of bionic egg-shaped shells in internal high-pressure bulging

Sun,

Shen,

Shi

et al. 2024

Int J Adv Manuf Technol

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A solid particle medium flexible bulging technology is proposed to solve the problems of low molding precision, poor stability, and uneven deformation that may occur when processing bionic egg-shaped shells by the traditional bulging process. By optimizing the mold parameters, such as the angle and height of the pusher head, the flow characteristics of the granular material are improved, resulting in improved machining accuracy and surface quality when molding egg-shaped plastic shells. In this paper, we utilize a ø0.8-1 mm yttria-stabilized zirconia ceramic bead to serve as a pressure-transfer medium during the granular media forming process. Several different shapes of pusher heads with cone angles of 45°, 60°, 75°, and 90° and heights of 10mm, 25mm, and 40mmwere designed and manufactured. The numerical model of simulation was verified by the analysis of strain inhomogeneity coefficient, and the maximum thinning rate at the apex of bulging of the egg-shaped test was measured and calculated. The results show that the maximum thinning rate at the apex of bulging is the largest for the pusher head with 45° cone angle and 25mm height, and the strain distribution is the most uniform and the expansion effect is the best. The study shows that the optimization of the process parameters of the pusher head shape can effectively improve the uniformity of the strain distribution and thickness distribution during the egg-shaped shell forming process, thus improving the machining accuracy of the plastic deformation of the bionic egg-shaped tube test piece.

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Enhanced granular medium-based tube and hollow profile press hardening

Cited by 27 publications

References 15 publications

Increasing the Lightweight Potential of Composite Cold Forging by Utilizing Magnesium and Granular Cores

Increasing the Lightweight Potential of Composite Cold Forging by Utilizing Magnesium and Granular Cores

A state of the art review of hydroforming technology

Influence of unidirectional loading pusher head structure on the deformation law of bionic egg-shaped shells in internal high-pressure bulging

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