Some aspects of barrelling in elliptical shaped billets of aluminium during cold upset forging with lubricant

Baskaran, K.; Narayanasamy, R.

doi:10.1016/j.matdes.2006.04.018

Cited by 15 publications

(10 citation statements)

References 14 publications

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“…In recent studies [10][11], barreling phenomenon was investigated experimentally at various friction and geometrical conditions. The radius of curvature of the barrel was expressed as a function of height reduction depending on the maximum and minimum radii of the billet which can only be obtained by measuring compressed cylinder.…”

Section: Introductionmentioning

confidence: 99%

Determination of Barreling of Aluminum Solid Cylinders During Cold Upsetting Using Genetic Algorithm

Kanca¹,

Eyerci̇oğlu

Günen³

et al. 2019

Matéria (Rio J.)

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This study presents Genetic Programming models for the formulation of barreling of aluminum solid cylinders during cold upsetting based on experimental results. The maximum and minimum radii of the barreled cylinders having different aspect ratio (d/h= 0.5, 1.0 and 2.0) were measured for various frictional conditions (m=0.1-0.4). The change in radii with respect to height reduction showed different trends before and after folding, therefore, the corresponding reduction ratios of folding were also determined by using incremental upsetting. Genetic programming models were prepared using the experimental results with the input variables of the aspect ratio, the friction coefficient, and the reduction in height. The minimum and maximum barreling radii were formulated as output taking the folding into consideration. The performance of proposed GP models are quite satisfactory (R 2 = 0.908-0.998).

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Section: Introductionmentioning

confidence: 99%

Determination of Barreling of Aluminum Solid Cylinders During Cold Upsetting Using Genetic Algorithm

Kanca¹,

Eyerci̇oğlu

Günen³

et al. 2019

Matéria (Rio J.)

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“…K. Baskaran, R. Narayanasamy 2008 [13] studied the effects of the initial aspect ratio on the work hardening behaviour during the cold upsetting under different stress state conditions. K. Baskaran and R. Narayanasamy 2008 [14] studied the bulging characteristics of preformed irregularly shaped pure aluminium billets (Elliptical billets) during cold upset forging using lubricant on both sides under different stress. K. Baskaran, R. Narayanasamy 2008 [5] studied the effect of various stress ratio parameters ( / z ), ( m / z ), ( �/ z ) and ( m / � ) on cold upset forging of commercially pure aluminium solid billets and on the measured barrel radius namely major and minor axis and on the percentage height reduction.…”

Section: Introductionmentioning

confidence: 99%

Experimental and Theoretical Study of Hardness and Grain Size Variation in Cold Upset for Pure Copper Cylinder

Hassan¹,

Saleh²,

Jibar³

2015

ujme

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In this work, the influence of varied deformation percentages on the hardness and grain size, effective strain variation during simple upsetting is studied. Also, hardness variation in a typical cold upset forging process is predicted by relating hardness and effective strain evolution in a simple upsetting operation empirically. Five different deformation percentages, (13%, 17%, 32.4%, 41%, 50%), are considered for experimentation. Ring compression tests were conducted to determine the friction factor "m". The upset-forging tests were conducted at room temperate and for different deformation percentage on the pure copper cylindrical specimens of 30 mm diameter with aspect ratio (h o /d o) of 1.0. The distribution of hardness in the cold upset specimen was measured using the Brinell Hardness Tester. Also, this work discussing metallographic study of the upset specimens. The micrograph of samples is processed with the "Adobe Photoshop CS2" program and then applying the "Image J" program for estimating the average grain size. The upsetting operation was simulated using a commercial finite element code, ANSYS ver11.0. The results show that the finite element procedure is effective procedure to simulating cold upsetting process with maximum error (7.7%).

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“…If friction is considered to be non-existent in the die/ work-piece, it can be presumed that deformation in the cylinder is uniform and the free surface of the cylinder will remain straight during compression. However, it has been observed that the use of lubricants reduces the degree of bulging (Baskaran and Narayanasamy, 2008). Kulkarni and Kalpakjian studied the barrelling condition with a sample of free deformation with Al 7075 specimen and show that the barrelling surface profile is circle (Kulkarni et al, 1969).…”

Section: Introductionmentioning

confidence: 99%

On materials flow using different lubricants in upsetting process

Misirli

2014

Industrial Lubrication and Tribology

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Purpose -The purpose of this paper is to apply the upsetting process to cylindrical specimens using flat end dies in which three types of lubricants were used. In many industrial processes, friction and lubrication have major advantages and are key during the metal forming process. Upset forging is a process which increases the diameter of the work-piece by compressing its length. Design/methodology/approach -The materials flow for various materials using different lubricants in upsetting was investigated in this study. AISI 304 austenitic-stainless steel and commercially pure aluminium (Al99.7) were used as the test materials. The upsetting process was applied to the cylindrical specimens using flat end dies. Three types of lubricants, namely, grease, graphite and SAE 40 oil, were used in this study. Experiments were performed using a hydraulic press, which has 5 mm/s ram speed, with a capacity of 150 metric tons. On the other hand, finite element methods (FEMs) have been carried out to analyse the forming performance for displacement prediction in the barrelling process. Findings -The results showed that the measured radius of the curvature of the barrel seemed to confirm the calculation values used before the initiation of the experimental process. It has been observed that the surface roughness had no considerable effect on the barrelling contour changes on the free surfaces, as it showed an increasing deformation ratio for all materials and lubricant types. However, minimum friction at the interface seems to occur with the grease lubricant. The present analyses show that FEMs, which can be used in the rapid prediction of required barrelling process displacements, are more suitable for use in a pressure distribution analysis for the development of the barrelling radius. Research limitations/implications -It would be interesting to search the material flow for more different materials and lubricants. It could be a good idea if future work could be concentrated on the material flow on upsetting by using different lubricants. Practical implications -Open-die forging, which is also known as the upsetting process, is one of the simplest forging operations used in bulk deformation processes. This operation can be explained as a solid work-piece which is positioned between two flat dies, and then with the aid of compression, the height of the work-piece is reduced under controlled working parameters during the upsetting process, in which friction and surface roughness are the major parameters playing an important role on the material flow. In a cold upsetting process, one of the undesirable conditions is that barrelling occurs as a consequence of friction between the work-piece and the die surfaces. The existence of this frictional constraint directly affects the plastic deformation of the work-piece, as friction causes barrelling in upsetting processes. However, it has been observed that the use of lubricants reduces the degree of bulging. Social implications -This paper will be useful for industrial applications. ...

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Some aspects of barrelling in elliptical shaped billets of aluminium during cold upset forging with lubricant

Cited by 15 publications

References 14 publications

Determination of Barreling of Aluminum Solid Cylinders During Cold Upsetting Using Genetic Algorithm

Determination of Barreling of Aluminum Solid Cylinders During Cold Upsetting Using Genetic Algorithm

Experimental and Theoretical Study of Hardness and Grain Size Variation in Cold Upset for Pure Copper Cylinder

On materials flow using different lubricants in upsetting process

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