Skip to main content

FE modeling of warm flanging process of large T-pipe from thick-wall cylinder

Abstract

The large T-branch pipe made from the thick-wall cylinder is an important part in power, petroleum, and chemical equipment. The warm flanging process is used to manufacture the high-performance large T-branch pipe from thick-wall cylinder. The warm flanging process has a bulk-forming characteristic with heterogeneous temperature field and represents very different from the sheet flanging process. The finite element method is adopted to study the warm flanging process of large T-branch pipe due to complex local heating and local deformation. A viscoplastic FE model was built to simulate the whole process in the same process, including heating, forming, cooling, and relevant elastic springback. Only one set of mesh was used to ensure the connection of heating and forming, which was never proposed in the warm flanging process before. The experiment was conducted to verify the proposed model by comparing the geometry and defects. Accordingly, two kinds of typical defects, buckling and wrinkling, were found in both of the simulation and experiment results. And, the reasons of defects were investigated with the stress and metal flow analysis. The short lower die leads to the buckling. Due to the ellipse outer edge, the uneven rebound makes wrinkling at the ends of the process. Three relevant improved methods, lengthening the lower die, increasing the fillet of the upper die, and increasing the radius of the upper die, were proposed and studied to decline the defects.

This is a preview of subscription content, access via your institution.

References

  1. 1.

    Thipprakmas S, Phanitwong W (2012) Finite element analysis of flange-forming direction in the hole flanging process. Int J Adv Manuf Technol 61(5):609–620

    Article  Google Scholar 

  2. 2.

    Livatyali H, Kinzel GL, Altan T (2003) Computer aided die design of straight flanging using approximate numerical analysis. J Mater Process Technol 142(2):532–543

    Article  Google Scholar 

  3. 3.

    Lin HS, Lee CY, Wu CH (2007) Hole flanging with cold extrusion on sheet metals by FE simulation. Int J Mach Tool Manu 47(1):168–174

    Article  Google Scholar 

  4. 4.

    Li C, Yang Y, Li S (1995) Deformation analysis and die-design principles in shrink curved flanging. J Mater Process Technol 51(1):164–170

    Google Scholar 

  5. 5.

    Asnafi N (1999) On stretch and shrink flanging of sheet aluminium by fluid forming. J Mater Process Technol 96(1–3):198–214

    Article  Google Scholar 

  6. 6.

    Feng X, Lin Z, Li S, Xu W (2004) Study on the influences of geometrical parameters on the formability of stretch curved flanging by numerical simulation. J Mater Process Technol 145(1):93–98

    Article  Google Scholar 

  7. 7.

    Worswick MJ, Finn MJ (2000) The numerical simulation of stretch flange forming. Int J Plast 16(6):701–720

    Article  MATH  Google Scholar 

  8. 8.

    Wang CT, Kinzel G, Altan T (1995) Failure and wrinkling criteria and mathematical modeling of shrink and stretch flanging operations in sheet-metal forming. J Mater Process Technol 53(3–4):759–780

    Article  Google Scholar 

  9. 9.

    Hu P, Li DY, Li YX (2003) Analytical models of stretch and shrink flanging. Int J Mach Tool Manu 43(13):1367–1373

    Article  Google Scholar 

  10. 10.

    Chen ZT, Worswick MJ, Lloyd DJ (2006) Experimental study of the stretch flange formability of al-mg sheet. Mater Sci Forum 519-521:967–972

    Article  Google Scholar 

  11. 11.

    Montanari L, Cristino VA, Silva MB, Martins PAF (2013) A new approach for deformation history of material elements in hole-flanging produced by single point incremental forming. Int J Adv Manuf Technol 69(5):1175–1183

    Article  Google Scholar 

  12. 12.

    Vafaeesefat A, Khanahmadlu M (2011) Comparison of the numerical and experimental results of the sheet metal flange forming based on shell-elements types. Int J Precis Eng Manuf 12(5):857–863

    Article  Google Scholar 

  13. 13.

    Sklenička V, Kuchařová K, Svobodová M, Kvapilová M, Král P, Horváth L (2016) Creep properties in similar weld joint of a thick-walled p92 steel pipe. Mater Charact 119:1–12

    Article  Google Scholar 

  14. 14.

    Dang L, Yang H, Guo LG, Shi L, Zhang J, Zheng WD (2015) Drx rules during extrusion process of large-scale thick-walled inconel 625 pipe by FE method. Trans Nonferrous Metals Soc China 25(9):3037–3047

    Article  Google Scholar 

  15. 15.

    An HP, Liu JS (2011) Research on new thermal hole flanging process of connection tube forming in heavy nuclear power thick-wall head. Mater Sci Forum 704-705:119–123

    Article  Google Scholar 

  16. 16.

    Chen XW, Zhao JW, Jung DW (2010) Improvement of hole flanging product forming process using finite element simulation. Adv Mater Res 97-101:344–347

    Article  Google Scholar 

  17. 17.

    Zhalehfar F, Hashemi R, Hosseinipour SJ (2015) Experimental and theoretical investigation of strain path change effect on forming limit diagram of aa5083. Int J Adv Manuf Technol 76(5):1343–1352

    Article  Google Scholar 

  18. 18.

    Cao CH, Hua L, Liu SL (2009) Flange forming with combined blanking and extrusion process on sheet metals by FEM and experiments. Int J Adv Manuf Technol 45(3):234–244

    Article  Google Scholar 

  19. 19.

    Yu X, Chen J, Chen J (2016) Influence of curvature variation on edge stretchability in hole expansion and stretch flanging of advanced high-strength steel. Int J Adv Manuf Technol 86:1083–1094

    Article  Google Scholar 

  20. 20.

    Elbitar T, Gemeal A (2008) Finite element analysis of deep drawing and hole flanging processing of an oil filter cover. Int J Mater Form 1(1):125–128

    Article  Google Scholar 

  21. 21.

    Cao T, Lu B, Cao J, Chen J (2017) Experimental investigations on the forming mechanism of a new incremental stretch-flanging strategy with a featured tool. Int J Adv Manuf Technol online: doi:10.1007/s00170-017-0355-5

  22. 22.

    Viskanta R (1993) Heat transfer to impinging isothermal gas and flame jets. Exp Thermal Fluid Sci 6(1):103–107

    MathSciNet  Google Scholar 

  23. 23.

    Takuda H, Mori K, Masuda I, Abe Y, Matsuo M (2002) Finite element simulation of warm deep drawing of aluminium alloy sheet when accounting for heat conduction. J Mater Process Technol 120(1–3):412–418

    Article  Google Scholar 

  24. 24.

    Lambiase F (2015) Clinch joining of heat-treatable aluminum aa6082-t6 alloy under warm conditions. J Mater Process Technol 225:421–432

  25. 25.

    Behrens BA, Bouguecha A, Vucetic M, Bonhage M, Malik IY (2016) Numerical investigation for the design of a hot forging die with integrated cooling channels. Proc Technol 26:51–58

    Article  Google Scholar 

  26. 26.

    Zhang D-W, Ou H (2016) Relationship between friction parameters in coulomb-Tresca friction model for bulk metal forming. Tribol Int 95:13–18

    Article  Google Scholar 

  27. 27.

    Leu DK (1996) Finite-element simulation of hole-flanging process of circular sheets of anisotropic materials. Int J Mech Sci 38(8):917–933

    Article  MATH  Google Scholar 

Download references

Author information

Affiliations

Authors

Corresponding author

Correspondence to Da-Wei Zhang.

Rights and permissions

Reprints and Permissions

About this article

Verify currency and authenticity via CrossMark

Cite this article

Ben, NY., Zhang, DW., Liu, N. et al. FE modeling of warm flanging process of large T-pipe from thick-wall cylinder. Int J Adv Manuf Technol 93, 3189–3201 (2017). https://doi.org/10.1007/s00170-017-0739-6

Download citation

Keywords

  • Flanging
  • FE model
  • Thick-wall cylinder
  • Thermal