Forming of thin-walled hollow spheres using sacrificial polymer mandrels

Theoretical analysis and finite element method were used to simulate the cold nosing process of commercial purity Aluminum tubes into conical and hemispherical dies. The influences of process parameters, namely initial tube wall thickness, conical semi-die angle and coefficient of friction were investigated. The results of the nosing process were obtained in terms of load-displacement curves, thickness distribution of deformed parts, the nosing ratios and strain distributions. According to these finding, the final shape and defects of the product can also be predicted. Experimental work was carried out to verify the simulation results. A new developed setup design was proposed to improve the product quality. Two adjacent punches were used: one with a front plunger and the other was an outer sleeve to constrain the tube. It could be observed that the load increase with increasing the tube wall thickness, semi die angle and coefficient of friction. The nosing ratio increases as wall thickness increases. Comparison between analytical and FE predictions to the experimental results showed good agreement.

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Section: An Introduction and Literature Surveymentioning

confidence: 59%

“…Total incremental workThe total incremental work is equal the sum of increment work of bending work, increment work of unbending work, increment work in friction zone, and incremental work of tube contraction work. δWᵼ = δWв + δWu + δWғ + δWᴄ(5) …”

mentioning

confidence: 99%

Study of Aluminum Tube Cold Nosing Process Into Conical and Hemispherical Dies

Abdelhameed

Alabden

Abdelrahman

et al. 2022

Journal of Advanced Engineering Trends

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“…The polymer mandrel was utilized to provide an internal support in the tube to get hollow spheres of uniform wall thickness with a single-stage nosing process. Also, they obtained a good agreement between the FE and experimental results Alves et al [5]. An analysis for nosing process using FEM was conducted to study the effect of different parameter on stainless steel tube with conical die.…”

Section: Introductionmentioning

confidence: 75%

Study of Aluminum Tube Cold Nosing Process Into Conical and Hemi-Spherical Dies With Different Coefficients of Friction

2020

Journal of the Egyptian Society of Tribology

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Theoretical analysis and finite element method were used to simulate the cold nosing process of commercial purity Aluminum tubes into conical and hemispherical dies. The influences of process parameters, namely initial tube wall thickness, conical semi-die angle were investigated. The effect of surface conditions on the load/displacement curve in the nosing process was investigated. The results of the nosing process were obtained in terms of load-displacement curves, thickness distribution of deformed parts, the nosing ratios and strain distributions. According to these finding, the final shape and defects of the product can also be predicted. Experimental work was carried out to verify the simulation results. A new developed setup design was proposed to improve the product quality. Two adjacent punches were used: one with a front plunger and the other was an outer sleeve to constrain the tube. It could be observed that the load increase with increasing the tube wall thickness and semi die angle. The load increased with increasing the coefficient of friction to overcome friction between the die and tube. The nosing ratio increases as wall thickness increases. Comparison between analytical and FE predictions to the experimental results showed good agreement.

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“…In fact, the removal of thermoplastics by melting is time-consuming and likely to produce toxic gases, and the alternative of using solvents is constrained by environmental issues. 15…”

Section: Introductionmentioning

confidence: 99%

“…Their work demonstrates the feasibility of thermoplastics to assist material flow and prevent collapse by buckling during injection forging of thick-walled tubes, but does not address the problem of its removal from the final shaped components. In fact, the removal of thermoplastics by melting is time consuming and likely to produce toxic gases, and the alternative of using solvents is constrained by environmental issues 15 .…”

mentioning

confidence: 99%

Pressure-assisted forming of non-concentric tubular cross sections with solid medium

Alves

Nielsen

Martins

2016

Proceedings of the Institution of Mechanical Engineers, Part B:

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Forming of thin-walled hollow spheres using sacrificial polymer mandrels

Cited by 16 publications

References 7 publications

Study of Aluminum Tube Cold Nosing Process Into Conical and Hemispherical Dies

Study of Aluminum Tube Cold Nosing Process Into Conical and Hemispherical Dies

Study of Aluminum Tube Cold Nosing Process Into Conical and Hemi-Spherical Dies With Different Coefficients of Friction

Pressure-assisted forming of non-concentric tubular cross sections with solid medium

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