Finite Element Simulation of the Cold Expansion Process with Split Sleeve in 7075 Aluminum Alloy

Liu, Kuan-Yu; Zhou, Li; Yang, Xiaotao; Li, Ming; Wang, Weiwei; Zhu, Weijin

doi:10.1007/s40032-020-00648-6

Cited by 6 publications

(1 citation statement)

References 11 publications

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“…5(a)), and the diameter of the convex hull is slightly larger than the hole diameter. [18][19][20][21][22][23] When the convex hull completely passes through the hole, the hole wall material experiences compressive stress, resulting in the strengthening effect. This study initially constructs a nite element model for hole expansion using the single convex hull expansion tool.…”

Section: Finite Element Modelmentioning

confidence: 99%

Design of a novel cold expansion tool for deep small holes based on FEM simulations and experimental study

Wang,

Lei,

Zeng

et al. 2024

Int J Adv Manuf Technol

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Cold hole expansion is a crucial technology for enhancing the fatigue life of hole structures. This paper presents the design and optimization of a novel multi-convex hulls expansion tool for deep small holes in Inconel 718 superalloy using the nite element method (FEM) and experimental techniques. The results from the FEM model, which was used to investigate the compressive residual stress (CRS) distribution and contact force during the expansion process, indicate that the curved single convex hull(CSCH) structure is more suitable for deep small hole expansion (DSHE). However, accounting for the strength limitations of the actual expansion tool, a multi-convex hulls expansion tool structure was proposed. The FEM model was employed to compare the effects of various tool structures on the hole wall CRS distribution and the contact force during the expansion process. The obtained optimal parameters for enhancing deep small holes in Inconel 718 superalloy under high temperature and high load conditions are as follows: expansion section hull spacing l 1 = 0.4 mm, taper ratio C = 0.008, number of convex hulls in the sizing section n = 10, and sizing section hull spacing l 2 = 1 mm. Moreover, an optimized convex hull expansion amount allocation scheme was obtained through an experimental study. The results of the FEM simulations and experimental study demonstrate that the optimized multi-convex hulls expansion tool (with an expansion rate of 1.92%) can induce the formation of a high CRS layer and a re ned surface without causing signi cant microcracks in the hole walls.

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