Forming characteristics of thin-walled tubes manufactured by free bending process-based nontangential rotation bending die

Hu, Shenghan; Cheng, Cheng; Abd El-Aty, Ali; Zheng, Shuo; Wu, Cong; Luo, Haoran; Guo, Xunzhong; Tao, Jie

doi:10.1016/j.tws.2023.111313

Cited by 7 publications

(1 citation statement)

References 19 publications

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“…Presently, shaping these components poses a significant challenge because of the high strength and relatively low ductility of AISI 304 SS at ambient temperatures. Moreover, the material’s high strength contributes to the issue of springback in thin-walled parts after forming, compromising their dimensional precision [ 4 , 5 ]. Thus, Jerzy et al mentioned in their study that the mechanical properties of thin-walled models created using 3D printing technology significantly vary from those manufactured via forming technologies [ 6 , 7 , 8 ].…”

Section: Introductionmentioning

confidence: 99%

Finite Element Analysis and Experimental Study of Manufacturing Thin-Walled Five-Branched AISI 304 Stainless Steel Tubes with Different Diameters Using a Hydroforming Process

El-Aty,

Xu,

Xie

et al. 2023

Materials

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This study aims to investigate the feasibility of hydroforming (HF) technology coupled with response surface optimization for producing high-quality five-branched AISI 304 stainless steel tubes with different diameters, addressing the shortcomings of traditional manufacturing processes. Conventional techniques often result in issues with multiple consumables, low precision, and subpar performance. The research focuses on finding optimal forming parameters for a more effective process. Initial attempts at a five-branched tube proved unfeasible. Instead, a multi-step forming approach was adopted, starting with the formation of the upper branch tube followed by the two reducing lower branch tubes, a strategy termed “first three, then five”. This method, enhanced by a subsequent solid solution treatment, yielded promising results: the combined height of the upper and lower branches was 141.1 mm, with a maximum thinning rate of 26.67%, reduced to 25.33% after trimming. These outcomes met the product usage requirements. Additionally, the study involved designing and developing dies for manufacturing five-branched tubes with different diameters using servo HF equipment. The effectiveness of the multi-step forming process and parameter combinations was confirmed through experimental validation, aligning closely with the FE simulation results. The maximum thinning rate observed in the experiments was 27.60%, indicating that FE simulation and response surface methodology can effectively guide the production of high-quality parts with superior performance.

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