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Multistage Axial Hydro-Forging Sequence: A New Forming Approach for Manufacturing of Double-Stepped Tubes

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Abstract

To manufacture the large-expansion-ratio double-stepped tube without thinning, a new approach known as multistage axial hydro-forging sequence has been proposed in this study. The whole forming process is divided into five stages. Compared with traditional tube hydroforming, the thickness can be increased by axial compression deformation to reduce the thinning ratio and enhance the forming capacity of the tube in hydro-forging stage and double-stepped hydro-forging stage, respectively. The proposed multistage axial hydro-forging sequence process was implemented by experiments along with the finite element simulation to validate its feasibility. The suitable loading path to prevent defects such as wrinkle and thinning was discussed. The results showed that double-stepped tube with large expansion ratio can be produced successfully with movable dies’ design. There is no thinning in the final tube, particularly in all stepped area, and a better thickness distribution could be achieved. As a result, the proposed multistage axial hydro-forging sequence can be a feasible forming approach for the fabrication of large-expansion-ratio double-stepped tubes with high reliability.

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Acknowledgments

This study was supported by the National Natural Science Foundation of China (Grant No. 51775134 and No. 51475121). The authors would like to express their sincere appreciation to these funding organizations.

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Authors and Affiliations

  1. School of Materials Science and Engineering, Harbin Institute of Technology at Weihai, Weihai, 264309, China

    Lei Sun, Caiyuan Lin, Zhigang Fan, Hang Li, Guodong Wang & Guannan Chu

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  1. Lei Sun
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  2. Caiyuan Lin
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  3. Zhigang Fan
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  4. Hang Li
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  5. Guodong Wang
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  6. Guannan Chu
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Correspondence to Guannan Chu.

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Sun, L., Lin, C., Fan, Z. et al. Multistage Axial Hydro-Forging Sequence: A New Forming Approach for Manufacturing of Double-Stepped Tubes. J. of Materi Eng and Perform 28, 6800–6808 (2019). https://doi.org/10.1007/s11665-019-04444-x

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  • DOI: https://doi.org/10.1007/s11665-019-04444-x

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