Diametrical growth in the forward flow forming process: simulation, validation, and prediction
- 420 Downloads
In the present study, the phenomenon of diametric growth in the forward flow forming process has been studied through finite element simulation and experimental investigation. Implicit integration scheme was employed in the simulation to achieve good accuracy for diametric growth prediction. The simulation results were in good agreement with the experiments for both types of materials considered, the aluminum alloy AA6061 and stainless steel SS304L. The residual stresses in the flow-formed parts were measured using x-ray diffraction to validate the model as well as provide the explanation for the diametric growth behavior. Based on the numerical and experimental results, an empirical function was proposed here to describe the amount of diametric growth in the flow-formed parts, which can be used as a predictive tool for dimension control in the flow forming process.
KeywordsFlow forming Finite element (FE) simulation Residual stresses Function for diametric growth prediction
Unable to display preview. Download preview PDF.
- 4.Hayama M (1966) Theoretical study of tube spinning. Bull Fac Eng 15:33–48Google Scholar
- 5.Gur M, Tirosh J (1982) Plastic flow instability under compressive loading during shear spinning process. J Manuf Sci Eng ASME 104(1):17–22Google Scholar
- 6.Danno A, Fong KS, Wong CC (2011) Effects of forming conditions on diameter accuracies of short cylindrical hollow cup after forward flow forming, In: Hirt G., Tekkaya, A.E. (Eds.), Proceedings of the 10th International Conference on Technology of Plasticity, ICTP 2011, Aachen, Germany, 574–579Google Scholar
- 13.Dierig H (1992) CNC spinning using adaptive control. In: VDI Fortschrittsberichte, R. 2 no. 252. VDI-Verlag, DüsseldorfGoogle Scholar
- 14.Xue KM, Wang Z, Lu Y, Li KZ (1997) Elasto-plastic FEM analysis and experimental study of diametral growth in tube spinning. J Mater Process Technol 69(1–3):172–175Google Scholar
- 23.Wong CC, Danno A, Fong KS (2010) Study on the deformation behaviour in the flow forming of cylindrical cups using finite element method. Steel Res Int 81–9:1002–1006Google Scholar
- 24.Song X (2010) Modelling residual stresses and deformation in metal at different scales., DPhil thesis, University of OxfordGoogle Scholar
- 25.DEFORM-3D Version 10.0 User's Manual, 2.4.4 Object type, Scientific Forming Technologies Corporation (SFTC), 2010Google Scholar
- 26.Wong CC, Danno A, Huang C, Aue-u-lan Y, Fong KS, Lun CL, Chin N, SIMTech Internal Report (2011) Development of rotary forming technology (phase 2): flow forming of high strength/high performance materials and larger size axisymmetrical components, C08-F-015Google Scholar