scholarly journals Analysis of Innovative Incremental Cold Forming Process for the Manufacturing of Aerospace Rotating Parts

2017 ◽  
Author(s):  
Marcos Pérez
Keyword(s):  
Strain Distribution ◽  
Heat Treatments ◽  
Forming Process ◽  
Cold Forming ◽  
Forging Process ◽  
Rotary Forging ◽  
Treated Condition ◽  
Cold Worked ◽  
Cold Rotary Forging ◽  
The Impact

Cold rotary forging is an innovative incremental metal forming process whose main characteristic is that the workpiece is only partially in contact with a conical tool, reducing therefore the required forging loads. However, in spite of many benefits of such a process, wide industrial implementation of rotary forging is not possible without proper understanding of material behaviour. In the present work, the capability of rotary forging process was explored for the manufacturing of flared cylindrical parts by cold forming. Another main aim was to assess the cold formability of high-strength materials for aerospace applications (martensitic stainless steels) under incremental processes. In order to understand the impact of rotary forging on the final properties of formed components, microstructural and mechanical analysis were performed. Microstructural and hardness analysis were conducted on both axial and transverse sections along the cold formed flange in order to study the grain flow orientation and strain distribution. In a similar fashion, mechanical test specimens were machined from different positions and orientations along the rotary forged component. Further analysis was performed on the components in the as-treated condition in order to understand the response of cold-worked Jethete M152 components to subsequent heat treatments. Microstructural and hardness analysis clearly reveals a strong grain reorientation and strain localization around “pickup“ defects (material attached to the upper tool) observed on the flange top surface, close to the flange edge. These results suggest that an excessive deformation is localized during the early stages of the flange formation. Another characteristic feature found in the rotary forged parts is the presence of a buckling phenomenon which appears in later stages of the rotary forging process. Strain hardening along with the increasing flange length requires higher levels of forging loads to keep forming the flange. This results into a significant accumulation of compressive stresses in the transition region between the flange and the straight region. Gradually the resultant compressive force exceeds the critical buckling load, leading to the occurrence of the buckling phenomenon. This latter issue determines the limit of the cold flaring process. This can help to determine the maximum length of the flange part, achievable in this process, which is of great importance for the design of these manufacturing technologies. From the mechanical testing results, large differences were found as a function of both position and orientation (axial, transverse) throughout the rotary forged components (anisotropic properties). Concerning the impact of heat treatments on cold-worked components, no differences were found in the as-treated condition, in terms of microstructural and mechanical properties between regions with a large difference in strain distribution. These results denote the normalizing effect of conventional hardening treatments on cold-worked Jethete M152 components, restoring the homogenous and isotropic properties across the whole component.

Study on the Formability of the Seam Welded Tube for Manufacturing the Drive Shaft

2013 ◽  
Vol 631-632 ◽  
pp. 708-712
Author(s):  
Bong Joon Kim ◽  
Eun Soo Park ◽  
Won Yong Byeon ◽  
Dal Joon Cha ◽  
Yong Nam Kwon
Keyword(s):  
Weld Line ◽  
Reduction Process ◽  
Rear Wheel ◽  
Drive Shaft ◽  
Cold Reduction ◽  
Roll Forming ◽  
Forming Process ◽  
Cold Forming ◽  
Geometrical Defects ◽  
The Impact

In this study, cold reduction process of the tubular metal is applied to manufacture the drive shaft for the rear wheel drive system. With this method during forming process, chip forming such as hobbing and broaching method is not involved. The manufacturing process is as follows; the tube which the sheet is formed and welded to by roll forming machine, is mounted on a suitable mandrel. This mandrel has an external toothing which corresponds to internal toothing of the final product. During axial moving and rotating of the workpiece, forming operation is carried out in lengthwise direction of the toothing. This forming rolls is positioned on the roll head and have a rolling axis vertical with the one of a mandrel. The total forming load needed in the cold reduction process is separated into numerous forming steps along the entire cylindrical length of the zone to be formed. In the process of cold forming on the profiled mandrel during the impact forming operation, material is pushed into depression of toothing of a mandrel mainly in a radial direction. Finally splines can be generated on the surface of components and overall elongated. If the process parameter such as the length of forming per 1rotation of 1roll is not optimized, the impact force from the rolls of the forming process causes geometrical defects. So the optimal parameters such as feeding and rotating speed of workpiece and the forming length should be properly determined. And the effects of the weld line positioning on the formability of the forming process is analyzed to minimize the generation of the defects such as crack on the surface of splined zone.

Study on the Large Module Spur Gear Cold Forming Process by Means of Numerical Simulation

2011 ◽  
Vol 189-193 ◽  
pp. 2642-2646 ◽  
Author(s):  
Qian Li ◽  
Yi Bian ◽  
Zhi Ping Zhong ◽  
Gui Hua Liu ◽  
Ying Chen
Keyword(s):  
Numerical Simulation ◽  
Simulation Method ◽  
Spur Gear ◽  
Cold Forging ◽  
Forming Process ◽  
Cold Forming ◽  
Forging Process ◽  
Flow Method ◽  
Precision Forging ◽  
Cold Precision Forging

The cold forging process of large module spur gear with four modules and 59mm breadth is performed by means of numerical simulation method. Two processes to forming such spur gears were compared by the simulation method, one is with the closed-die performing and extrusion in the finish-forging, the other is with divided-flow method in the finish-forging. Especially, the divided-flow method is analyzed in detail. The necessary reference and basis to realize practical cold precision forging process of spur gear with large modulus is provided eventually.

The Influence of the UOE-SAWL Forming Process on the Collapse Resistance of Deepwater Linepipe

2011 ◽  
Author(s):  
Luciano O. Mantovano ◽  
Mohamed R. Chebaro ◽  
Hugo A. Ernst ◽  
Marcos de Souza ◽  
Chris M. Timms ◽  
...  
Keyword(s):  
Thermal Ageing ◽  
Full Scale ◽  
Sensitivity Analyses ◽  
Experimental Chamber ◽  
Forming Process ◽  
Cold Forming ◽  
Collapse Resistance ◽  
Expansion Stage ◽  
Full Scale Tests ◽  
The Impact

The UOE-SAWL pipe manufacturing process introduces considerable plastic deformations and residual stresses to feedstock plate material. Previous experimental and analytical studies have demonstrated that the effects of this process, predominantly in its final expansion stage, significantly reduce the collapse resistance of deepwater linepipe. Finite element analyses, sensitivity analyses and full-scale tests were conducted by Tenaris and C-FER Technologies (C-FER) over the last several years to better comprehend the impact of cold forming on collapse resistance. This paper presents the findings of the latest segment of this ongoing study, the objective of which was to optimize the collapse resistance of UOE-SAWL linepipe by varying three key thermal ageing parameters: time, temperature and number of thermal cycles. Six X70M and four X80M UOE pipe samples were manufactured and thermally treated with varied parameters. Full-scale collapse and buckle propagation tests were then carried out in an experimental chamber that simulates deepwater conditions. These experimental results were evaluated with respect to collapse predictions from API RP 1111 and DNV OS-F101. Material and ring splitting tests were also performed on samples obtained from these pipes to better assess the extent of the UOE pipe collapse resistance recovery. The outcomes of this study will be employed to further optimize the collapse resistance of subsea linepipe in order to reduce material and offshore installation costs.

Model 3D Desain Struktur Baja Canai Dingin pada Rumah Sederhana 2 Lantai Berdasarkan SNI 7971-2013. (Hal. 9-17)

2018 ◽  
Vol 4 (2) ◽  
pp. 9
Author(s):  
Muhammad Ahdi Hafizha ◽  
Kamaludin Kamaludin
Keyword(s):  
Structural Models ◽  
Rolled Steel ◽  
Land Area ◽  
Forming Process ◽  
Cold Forming ◽  
Force Ratio ◽  
Profile Element ◽  
Cold Rolled ◽  
2D And 3D ◽  
The Impact

ABSTRAKIndonesia adalah negara berkembang dengan pertumbuhan pembangunan yang cukup tinggi, sementara luas lahan yang tersedia masih tetap dan terbatas. Akibat dari kondisi tersebut, berdampak pada kebutuhan akan rumah tinggal atau hunian akan semakin tinggi, Rumah sederhana 2 lantai yang layak dan kokoh berbasis ekonomis adalah solusi untuk masyarakat tersebut. Profil baja canai dingin adalah jenis profil baja yang memiliki ketebalan dimensi yang relatif tipis dengan rasio dimensi lebar setiap elemen profil terhadap tebalnya sangat besar, karena ketebalan dimensi profil relatif tipis, maka pembentukan profil dapat dilaksanakan menggunakan proses pembentukan dingin. Maka dari itu adanya model rumah sederhana 3D menggunakan profil baja canai yang praktis dan relatif murah adalah solusi masalah tersebut. Peneliti mengkhususkan mengetahui perbandingan gaya dalam dan rasio yang terjadi  pada model struktur 2D dan 3D. Hasil yang Didapat dari rasio balok yaitu 0,98 dan kolom 0,69.Kata kunci: baja canai, rumah, balok, kolom. ABSTRACTIndonesia is a developing country with relatively high development growth, while the available land area is still limited. As a result of these conditions, the impact on the need for residential or occupancy will be higher, simple and economically viable 2-storey house is a solution for the community. The profile of cold rolled steel is a type of steel profile that has a relatively thin dimensional thickness with the width dimension ratio of each profile element to a very large thickness. Because the profile thickness thickness is relatively thin, the profile formation can be performed using cold forming process. Therefore the existence of a simple 3D home model using a practical and relatively cheap steel roll profile is the solution of the problem. The researcher specializes in knowing the inner force ratio and the ratios that occur in 2D and 3D structural models. The results obtained from beam ratios are 0.98 and 0.69 columns.Keywords: cold formed, house, beams, coloum.

Effect of Position between Upper Die and Workpiece on Cold Rotary Forging

2011 ◽  
Vol 189-193 ◽  
pp. 2547-2552 ◽  
Author(s):  
Xing Hui Han ◽  
Lin Hua
Keyword(s):  
Metal Forming ◽  
Interactive Effects ◽  
Fe Model ◽  
Software Environment ◽  
Forging Process ◽  
Rotary Forging ◽  
Forming Technology ◽  
Cylindrical Workpiece ◽  
Forging Force ◽  
Cold Rotary Forging

Cold rotary forging is an advanced but very complex incremental metal forming technology with multi-factors coupling interactive effects. The position between the upper die and the workpiece has a significant effect on the cold rotary forging process. In the current work, a 3D elastic-plastic dynamic explicit FE model of cold rotary forging of a cylindrical workpiece is developed under the ABAQUS software environment and its validity has been verified experimentally. On the basis of this reliable 3D FE model, the effects of the position between the upper die and the workpiece on the cold rotary forging process have been thoroughly revealed. The results show that with increasing the distance between the pivot point of the upper die and the centre of the workpiece, the deformation of the workpiece becomes more inhomogeneous and the maximum axial forging force and forging moment gradually increase. The results of this research not only provide valuable guidelines for the installation and adjustment of dies in the cold rotary forging process, but also help to better understand the deformation mechanisms of cold rotary forging.

Microstructural Behaviour in Rotary Forging of Inconel 718

2012 ◽  
Vol 504-506 ◽  
pp. 169-174 ◽  
Author(s):  
Ángela Mangas ◽  
Maite Santos ◽  
Juan San José ◽  
Garbiñe Atxaga ◽  
Olatz Adarraga
Keyword(s):  
Grain Size ◽  
Inconel 718 ◽  
Forming Process ◽  
Numerical Work ◽  
Forging Process ◽  
Rotary Forging ◽  
Recrystallization Mechanism ◽  
Microstructural Behavior

In the work developed in this paper, the model of the microstructural behavior of Inconel 718 for the rotary forging process is studied. This process is presented as an alternative to the conventional forging. The window process of Inconel 718 is very narrow, so the requirements for manufacturing Inconel are very restrictive. Optimization of the rotary forging process was carried out in order to manufacture Inconel pieces with good microstructural distribution. Microstructural specification was given by aeronautic sector. Numerical work was done in order to simulate the microstructural behavior during the forming process. This method was used: a) to understand the recrystallization mechanism that take place in rotary forging processes, b) to compare the microstructure between a piece done in conventional forging and another done in rotary forging and c) to study the influence of the initial grain size in the final piece.

Intermediate Slabs and Optimization in Forging Process of Balance Elbow by FEM

2014 ◽  
Vol 721 ◽  
pp. 127-130
Author(s):  
Bo Jun Xiong ◽  
Ke Lu Wang ◽  
Jun Fang ◽  
Yun Huang
Keyword(s):  
Temperature Distribution ◽  
Strain Distribution ◽  
Simulation Analysis ◽  
Effective Strain ◽  
Maximum Load ◽  
Load Force ◽  
Fe Model ◽  
Forming Process ◽  
Rigid Plastic ◽  
Forging Process

Based on Deform-3D software, a 3D rigid-plastic FE model of forging forming process was established, then simulation analysis effective strain distribution, temperature distribution and load-stroke curve of three kinds of intermediate slabs (S1,S2,S3) in forging process. The results show that the optimized intermediate slab (S3) of effective strain distribution and temperature distribution is most homogeneous. And the maximum load force is minimum, the Shapes and dimensions of forging reach the preset value.

scholarly journals Estimation of fatigue life for clinched joints with the Local Strain Approach incorporating the impact of cold forming to cyclic material properties

2021 ◽  
Vol 349 ◽  
pp. 04005
Author(s):  
Boris Spak ◽  
Maximilian Schlicht ◽  
Karina Nowak ◽  
Markus Kästner ◽  
Pascal Froitzheim ◽  
...  
Keyword(s):  
Fatigue Life ◽  
Material Properties ◽  
Lightweight Design ◽  
Base Material ◽  
Local Strain ◽  
Small Scale ◽  
Forming Process ◽  
Cold Forming ◽  
Finite Element Software ◽  
The Impact

Joining by forming is a commonly applied technique in the automotive industry to assemble parts of thin metal sheets to meet the demands of lightweight design. The joining operation induces changes in material behaviour due to cold forming, that can be observed in increased hardness in the area close to the joint neck compared to the base material. Complex geometrical features of clinched joints on a small scale and the lack of non-destructive methods to track local stresses and strains require a combined approach utilizing numerical and experimental techniques. Numerical process and loading simulation are performed utilizing commercial finite element software LS-Dyna®. Hardness measurements in the joint are carried out to assess the impact of forming operation. Cyclic material properties are derived from Vickers hardness to estimate fatigue life with the Local Strain Approach using the damage parameter PSWT. Fatigue life estimation with failure criterion crack initiation obtained from simulation results is compared to those from experiments. The results obtained indicate that the Local Strain Approach is suitable for fatigue life estimations of clinched joints under constant amplitude loading as long as the influence of the forming process is considered.

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