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Flow-induced folding in multi-scaled bulk forming of axisymmetric flanged parts and its prediction and avoidance

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Abstract

The quality of manufactured parts and the efficiency of forming processes are crucial in deformation-based manufacturing. In product miniaturization and micro-manufacturing, size effect induces many unknowns. Flow-induced folding related to size effect is one of them and has not yet been fully studied. In this research, the formation mechanism of folding defects in axisymmetric bulk forming was investigated, and a design-based method was employed to evaluate different tooling and process route designs for making a case-study multi-flanged part with three features and to explore the design-based avoidance of folding defects. In addition, a design evaluating framework of folding-free bulk forming was proposed, implemented, and validated. Via analysis of the material flow, energy consumption, folding formation, and product precision of the four proposed forming processes for the case-study part, an upsetting-extrusion forming method via using a nested punch was found to be the most desirable. It was then implemented in the physical forming with three size scales. The results revealed that the flow-induced folding in the macropart was severe and regularly circuitous, but it is slight and irregular in meso- and micro-scale. These findings are useful in the defect-free forming of multi-flanged structures and multi-scaled axisymmetric parts.

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All the data and material are available upon request to the corresponding author.

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Funding

This research was supported by the projects of ZE1W and BBAT from The Hong Kong Polytechnic University, the National Natural Science Foundation of China (NSFC) key project of No. 51835011, and the General Research Fund (GRF) project of 15223520.

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Authors and Affiliations

  1. Department of Mechanical Engineering, The Hong Kong Polytechnic University, Hung Hom, Kowloon, Hong Kong, China

    Jun-Yuan Zheng, Jie Yi Chen Fang & Ming Wang Fu

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  1. Jun-Yuan Zheng
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  2. Jie Yi Chen Fang
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  3. Ming Wang Fu
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Contributions

Jun-Yuan Zheng: conceptualization, methodology, investigation, validation, visualization, writing — original draft, and writing — review and editing. Jie Yi Chen Fang: conceptualization, methodology, and investigation. Ming Wang Fu: conceptualization, supervision, resources, and writing — review and editing.

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Correspondence to Ming Wang Fu.

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Zheng, JY., Fang, J.Y.C. & Fu, M.W. Flow-induced folding in multi-scaled bulk forming of axisymmetric flanged parts and its prediction and avoidance. Int J Adv Manuf Technol 119, 5863–5883 (2022). https://doi.org/10.1007/s00170-021-08382-8

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