Flange forming at an arbitrary tube location through upsetting with a controllable deformation zone

Zhu, Shengfa; Zhuang, Xincun; Xu, Dongkai; Zhu, Yin; Zhao, Zhen

doi:10.1016/j.jmatprotec.2019.05.011

Cited by 19 publications

(8 citation statements)

References 16 publications

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“…In the upsetting process, the moving tools are the punch and counter-punch [51], while in extrusion the punch and moveable sleeve [52]. This kinematics of the tools prevent local buckling of the hollow workpiece wall; thus, making it possible to form relatively high flanges with wall thickness larger than that of the billet [53,54]. The process of extrusion with a moveable sleeve can be conducted in several stages, which makes it possible to produce flanges that have a more than twofold higher volume than those produced using the conventional radial extrusion technique [55].…”

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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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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“…When the process is performed in several stages or in combination with other techniques, e.g., upsetting in the tapered die cavity, it is possible to form flanges with a large diameter and height at the same time. Zhu et al [10] proposed a process that was similar to the above-mentioned movable sleeve extrusion method. In this process, the sleeve is fixed, and the punch moves along with a counterpunch that is pressed against the face-end of the flange formed.…”

Section: Introductionmentioning

confidence: 99%

“…. 1 2 3 4 5 6 7 8 9 10 11 (10) is then defined, and the least-squares method is used to determine the coefficients a and b, thus yielding Equation (11) that is plotted as a red straight line in Figure 10. Given the above, it can be stated that the maximum incremental extrusion force for forming a flange with a given diameter can be roughly determined using the obtained equation.…”

mentioning

confidence: 99%

Theoretical and Experimental Analysis of a New Process for Forming Flanges on Hollow Parts

Winiarski¹,

Gontarz²,

Samołyk³

2020

Materials

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The paper presented a new method for forming flanges on hollow parts by incremental radial extrusion. In the classic process of radial extrusion, additional rings were used to limit the free flow of material in the radial direction. The flange was formed progressively, using rings of increasing diameters. The proposed method was verified by numerical analysis and experimental tests. The numerical calculations were performed by the finite element method using the Deform-3D software package. Tubes made of aluminum alloy EN AW 6060 were used as billets. Laboratory tests were carried out using the Instron 1000 HDX testing machine. The objective of the study was to determine the validity of the proposed flange extrusion method. Results demonstrated that the new method made it possible to produce flanges with a relatively large diameter and uniform thickness, confirming the effectiveness of the proposed forming technique.

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“…The process presented in the study [12] is realised with top and bottom dies simultaneously moving and creating a closed impression of a fixed height. In the works [13,14] using the movable counter punch increases the height of the closed impression, which allows one to produce a flange with relatively significant heights in relation to the wall thickness of the tube billet. In the technologies based on extrusion with a movable sleeve, moving spontaneously as a result of pressure force of the deformed material [15] or powered independently from the punch [16,17] the volume of the closed impression increases along with the stage of the process.…”

Section: Introductionmentioning

confidence: 99%

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

Winiarski¹,

Bulzak²,

Wójcik³

et al. 2020

Adv. Sci. Technol. Res. J.

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The paper presents an innovative method of metal forming of hollow flanged elements. In this process, flanges are formed using a movable sleeve, which moves in the opposite direction to the punch. The movement of the sleeve causes a closed impression to open, due to which the flange is also formed in a semi-free impression. The tube billets were made of the 42CrMo4 grade steel deformed under the cold metal forming conditions. The calculations were conducted using the finite elements method in Deform-2D/3D. Various technological parameters of the process were analysed, among others the diameter of the flange and the initial height of the impression of the movable sleeve. On the basis of the obtained results, the limiting phenomena of the process were determined and the influence of the analysed technological parameters on these phenomena were presented.

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Flange forming at an arbitrary tube location through upsetting with a controllable deformation zone

Cited by 19 publications

References 16 publications

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

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

Theoretical and Experimental Analysis of a New Process for Forming Flanges on Hollow Parts

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

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