Experiments and simulation of shape and thickness evolution in multi-pass tube spinning

Roy, Biplov Kumar; Korkolis, Yannis P.; Arai, Yasuhiko; Araki, Wakako; Iijima, Takafumi; Kouyama, Jin

doi:10.1088/1742-6596/1063/1/012087

Cited by 6 publications

(1 citation statement)

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“…Traditionally, the representative part of the FES model can replace the whole model, considering the symmetry in terms of geometry and loading. For example, Joun et al [10] obtained consistent simulation results compared to experiments by using the 1/24 and 1/8 geometry of their axisymmetric flow forming workpiece, and Roy et al [11] even used the axisymmetric model to study the evolution of shape and thickness during flow forming in multiple passes. Of course, the results of such models are imperfect for complicated load paths because the parting planes are difficult to handle.…”

Section: Introductionmentioning

confidence: 95%

An accelerated simulating method for flow forming process through locally and dynamically rigidifying the workpiece

Dong¹,

Zhan

Lyu³

et al. 2023

Preprint

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Flow forming is a widely used process for manufacturing tubular parts in the aerospace and defense industries. In this process, the workpiece is produced locally and continuously under the action of mandrel and feed of roller(s), which requires a lengthy finite element simulation (FES) time. To speed up the FES, dynamic rigidifying the portion of workpiece which undergoes little or no deformation is an available method to reduce the amount of calculation. The mobile region that deforms plastically during the process can be identified based on the position of the roller(s) and then projected onto the designed workpiece to construct the rigid-flexible coupling model. This identification can be accelerated by clustering the elements of workpiece into a sequence of blocks along the axial or hoop direction, or both. Thus, the workpiece can be subdivided into blocks or simply into rigid and deformable parts along the intersections of the blocks. In addition, the partitioned workpiece is overlaid by a structured mesh to store the historical data during process and ensure accuracy. By integrating the above methods, the local and dynamic rigidification method can be applied to simulate the flow forming process via the secondary development of Abaqus. Comparing the precision and efficiency of models divided along diverse directions, the model divided along the axes has the optimal performance and can reduce the calculation time by 1/4 to 1/3. When the workpiece is cut only at the interfaces between rigid and deformable parts, the FES results for the large radius model show that rigidification performs well with large reduction.

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Section: Introductionmentioning

confidence: 95%