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

Winiarski, Grzegorz; Gontarz, A.; Samołyk, G.

doi:10.3390/ma13184088

Cited by 11 publications

(13 citation statements)

References 39 publications

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“…The development of capabilities of the energy method of power balance based on the expansion of the base of kinematic modules of complex configuration was addressed in a series of works [29][30][31][32][33][34][35][36]. Papers [29,30] suggested techniques for simplifying the power of plastic deformation forces using a minimizing function in a general form.…”

Section: Literature Review and Problem Statementmentioning

confidence: 99%

“…The authors identified the complication of the mathematical apparatus when deriving the value of the reduced deformation pressure (in an analytical form) inside the kinematic module of a triangular or trapezoidal shape with slanting boundaries. A series of works attempted to resolve the issues related to searching for techniques to simplify the expressions of the reduced deformation pressure and deriving the appropriate engineering formulae for calculating the force regime of cold extrusion processes [33,34,36]. The variation of manufacturing modes, tool configurations in production significantly expands the possibilities of cold extrusion processes, on the one hand.…”

Section: Literature Review and Problem Statementmentioning

confidence: 99%

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Designing a kinematic module with rounding to model the processes of combined radial-longitudinal extrusion involving a tool whose configuration is complex

Hrudkina

Aliiev

Марков

et al. 2021

EEJET

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It is advisable that parts whose shape is complex and which are made from solid or hollow blanks should be made by means of transverse and combined radial-longitudinal extrusion. The variation of manufacturing modes, tool configurations (in the form of chambers and rounding of the transitional sections of matrices) requires an adequate preliminary assessment of the force regime and the features of part shape formation. This paper has proposed a curvilinear kinematic module of the trapezoidal form for modeling radial-longitudinal extrusion processes in the presence of matrix rounding. Given the impossibility of using a quarter-circle boundary for the kinematically assigned possible velocity field, it has been proposed to use approximate curves in the form of z1(r) and z2(r). Taking into account the slightest deviation in the length of the arc of the approximate curve z1(r) and the area of the curvilinear trapezoid bounded by it relative to a quarter of the circle (not exceeding 0.8 % for any ratio), it has been recommended using this particular replacement. We have performed calculations of the value of the reduced deformation pressure inside the kinematic module with rounding taking into consideration the power of cutting forces at the border with adjacent kinematic modules. As an example, the devised module with rounding embedded in the estimation scheme of radial extrusion was analyzed. A significant impact of friction conditions on the force mode and the corresponding optimal value of the rounding radius have been identified. The resulting kinematic module makes it possible to expand the capabilities of the energy method for modeling cold extrusion processes involving the tools of complex form according to new deformation schemes. That could contribute to preparing recommendations on the optimal tool configuration and more active industrial implementation of these processes

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Section: Literature Review and Problem Statementmentioning

confidence: 99%

Section: Literature Review and Problem Statementmentioning

confidence: 99%

Designing a kinematic module with rounding to model the processes of combined radial-longitudinal extrusion involving a tool whose configuration is complex

Hrudkina

Aliiev

Марков

et al. 2021

EEJET

View full text Add to dashboard Cite

show abstract

“…To prevent the above mentioned phenomena, the process can be conducted with the use of limit rings for constraining free flow of metal in the flange forming zone. Studies have shown that incremental extrusion conducted with the use of both non-deformable rings [37] and deformable rings [38] results in significantly improved quality of extruded parts. The flange has a constant thickness and its maximum diameter is 30% bigger than that obtained in the process conducted without the use of a limit ring.…”

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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“…Another solution worthy of consideration is the new method for forming flanges on hollows parts by radial extrusion proposed by Winiarski et al [ 10 ]. The process was successfully applied to connect metal rings (sheets) to the metal tube ends, and is based on a force-fit joining mechanism relying on the residual normal pressures that are created at the contact interfaces after unloading.…”

Section: Introductionmentioning

confidence: 99%

Single-Stroke Attachment of Sheets to Tube Ends Made from Dissimilar Materials

et al. 2021

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This paper presents a new joining method by a forming process for attaching sheets to tube ends. The process consists of two different forming stages carried out sequentially in a single stroke. Firstly, the free tube end is flared by compression with a contoured die, then is squeezed (indented) against the sheet surface to create a mechanical interlocking. The new process is carried out at an ambient temperature and, in contrast to existing joining by forming operations based on tube expansion, it avoids seal welds, tube protrusions above the sheet surfaces, and machining of grooves on the sheet holes to obtain the form‑fit joints. The paper starts by analyzing the process deformation mechanics and its main operating variables and finishes by presenting examples that demonstrate its effectiveness for attaching sheets to tube ends made from polyvinylchloride and aluminum. Experimental and numerical simulation work provides support to the presentation.

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

Cited by 11 publications

References 39 publications

Designing a kinematic module with rounding to model the processes of combined radial-longitudinal extrusion involving a tool whose configuration is complex

Designing a kinematic module with rounding to model the processes of combined radial-longitudinal extrusion involving a tool whose configuration is complex

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

Single-Stroke Attachment of Sheets to Tube Ends Made from Dissimilar Materials

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