Skip to main content
SpringerLink
Log in

Integration of tube end forming in wire arc additive manufacturing: An experimental and numerical investigation

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Integration of tube end forming operations in metal additive manufacturing routes has a great potential for the fabrication of customized features in additively deposited hollow parts. This paper is focused on the integration of tube expansion with rigid tapered conical mandrels to highlight the advantages in the construction of overhanging flares derived from the elimination of support structures and prevention of humping. The work draws from the mechanical and formability characterization of stainless steel AISI 316L tubes produced by wire arc additive manufacturing (WAAM) to the experimental and numerical simulation of the construction of overhanging flares by tube expansion. Strain loading paths obtained from digital image correlation and finite element analysis combined with the strain values at the onset of necking and fracture allow determining the critical ductile damage that additively deposited tubes can safely withstand. Results show that despite formability of additively deposited tubes being influenced by a dendritic based microstructure, their performance is adequate for tube end forming operations, such as tube expansion, to be successfully integrated in metal additive manufacturing without the need of using expensive hardware and complex deposition strategies.

Graphical abstract

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

Similar content being viewed by others

Data availability

Authors confirm that the data and material supporting the findings of this work are available within the article.

References

  1. Jiang J, Xu X, Xiong Y, Tang Y, Dong G, Kim S (2020) A novel strategy for multi-part production in additive manufacturing. Int J Adv Manuf Technol 109:1237–1248. https://doi.org/10.1007/s00170-020-05734-8

    Article  Google Scholar 

  2. Daniyan I, Mpofu K, Daniyan L, Fameso F, Oyesola M (2020) Computer aided simulation and performance evaluation of additive manufacturing technology for component parts manufacturing. Int J Adv Manuf Technol 107:4517–4530. https://doi.org/10.1007/s00170-020-05340-8

    Article  Google Scholar 

  3. Lu X, Zhou YF, Xing XL, Shao LY, Yang QX, Gao SY (2017) Open-source wire and arc additive manufacturing system: formability, microstructures, and mechanical properties. Int J Adv Manuf Technol 93:2145–2154. https://doi.org/10.1007/s00170-017-0636-z

    Article  Google Scholar 

  4. Pragana JP, Pombinha P, Duarte VR, Rodrigues TA, Oliveira JP, Bragança IM, Santos TG, Miranda RM, Coutinho L, Silva CM (2020) Influence of processing parameters on the density of 316L stainless steel parts manufactured through laser powder bed fusion Proceedings of the Institution of Mechanical Engineers, Part B. J Eng Manuf 234:1246–1257. https://doi.org/10.1177/0954405420911768

    Article  Google Scholar 

  5. Murr LE, Martinez E, Amato KN, Gaytan SM, Hernandez J, Ramirez DA, Shindo PW, Medina F, Wicker RB (2012) Fabrication of metal and alloy components by additive manufacturing: examples of 3D materials science. Journal of Materials Research and technology 1:42–54. https://doi.org/10.1016/S2238-7854(12)70009-1

    Article  Google Scholar 

  6. DebRoy T, Wei HL, Zuback JS, Mukherjee T, Elmer JW, Milewski JO, Beese AM, Wilson-Heid A, De A, Zhang W (2018) Additive manufacturing of metallic components–process, structure and properties. Prog Mater Sci 92:112–224. https://doi.org/10.1016/j.pmatsci.2017.10.001

    Article  Google Scholar 

  7. Ford S, Despeisse M (2016) Additive manufacturing and sustainability: an exploratory study of the advantages and challenges. J Clean Prod 137:1573–1587. https://doi.org/10.1016/j.jclepro.2016.04.150

    Article  Google Scholar 

  8. Lefky CS, Zucker B, Wright D, Nassar AR, Simpson TW, Hildreth OJ (2017) Dissolvable supports in powder bed fusion-printed stainless steel. 3D Printing and Additive Manufacturing 4:3–11. https://doi.org/10.1089/3dp.2016.0043

    Article  Google Scholar 

  9. Ding Y, Dwivedi R, Kovacevic R (2017) Process planning for 8-axis robotized laser-based direct metal deposition system: a case on building revolved part. Robot Comput Integr Manuf 44:67–76. https://doi.org/10.1016/j.rcim.2016.08.008

    Article  Google Scholar 

  10. Yuan L, Pan Z, Ding D, He F, van Duin S, Li H, Li W (2020) Investigation of humping phenomenon for the multi-directional robotic wire and arc additive manufacturing. Robot Comput Integr Manuf 63:101916. https://doi.org/10.1016/j.rcim.2019.101916

    Article  Google Scholar 

  11. Kazanas P, Deherkar P, Almeida P, Lockett H, Williams S (2012) Fabrication of geometrical features using wire and arc additive manufacture. Proceedings of the Institution of Mechanical Engineers. Part B: Journal of Engineering Manufacture 226:1042–1051. https://doi.org/10.1177/0954405412437126

    Article  Google Scholar 

  12. Yoon HS, Lee JY, Kim HS, Kim MS, Kim ES, Shin YJ, Chu WS, Ahn SH (2014) A comparison of energy consumption in bulk forming, subtractive, and additive processes: review and case study. International Journal of Precision Engineering and Manufacturing-Green Technology 1:261–279. https://doi.org/10.1007/s40684-014-0033-0

    Article  Google Scholar 

  13. Seow CE, Coules HE, Wu G, Khan RH, Xu X, Williams S (2019) Wire arc additively manufactured Inconel 718: effect of post-deposition heat treatments on microstructure and tensile properties. Mater Des 183:108157. https://doi.org/10.1016/j.matdes.2019.108157

    Article  Google Scholar 

  14. Woodcock J (2014) Euromold roundup - bigger, bolder, busier. TCT. http://www.tctmagazine.com/blogs/jwblog/euromold-roundup-2013/. Accessed 1 August 2020

    Google Scholar 

  15. Merklein M, Junker D, Schaub A, Neubauer F (2016) Hybrid additive manufacturing technologies–an analysis regarding potentials and applications. Phys Procedia 83:549–559. https://doi.org/10.1016/j.phpro.2016.08.057

    Article  Google Scholar 

  16. Silva CMA, Bragança IMF, Cabrita A, Quintino L, Martins PAF (2017) Formability of a wire arc deposited aluminium alloy. J Braz Soc Mech Sci Eng 39:4059–4068. https://doi.org/10.1007/s40430-017-0864-z

    Article  Google Scholar 

  17. Pragana JPM, Cristino VAM, Bragança IMF, Silva CMA, Martins PAF (2020) Integration of forming operations on hybrid additive manufacturing systems based on fusion welding. International Journal of Precision Engineering and Manufacturing-Green Technology 7:595–607. https://doi.org/10.1007/s40684-019-00152-y

    Article  Google Scholar 

  18. Schulte R, Papke T, Lechner M, Merklein M (2020) Additive manufacturing of tailored blank for sheet-bulk metal forming processes. IOP Conf Ser Mater Sci Eng 967:12034

    Article  Google Scholar 

  19. Rosenthal S, Platt S, Jager RH, Gies S, Kleszczynski S, Tekkaya AE, Witt G (2019) Forming properties of additively manufactured monolithic Hastelloy X sheets. Mater Sci Eng A 753:300–316. https://doi.org/10.1016/j.msea.2019.03.035

    Article  Google Scholar 

  20. Ambrogio G, Gagliardi F, Muzzupappa M, Filice L (2019) Additive-incremental forming hybrid manufacturing technique to improve customised part performance. J Manuf Process 37:386–391. https://doi.org/10.1016/j.jmapro.2018.12.008

    Article  Google Scholar 

  21. Baptista RJS, Pragana JPM, Bragança IMF, Silva CMA, Alves LM, Martins PAF (2020) Joining aluminium profiles to composite sheets by additive manufacturing and forming. J Mater Process Technol 279:116587. https://doi.org/10.1016/j.jmatprotec.2019.116587

    Article  Google Scholar 

  22. Pragana JPM, Rosenthal S, Alexandrino P, Araújo A, Bragança IMF, Silva CMA, Leitão PJ, Tekkaya AE, Martins PAF (2021) Coin minting by additive manufacturing and forming. Proc Inst Mech Eng B J Eng Manuf 235:819–828. https://doi.org/10.1177/0954405420971128

    Article  Google Scholar 

  23. Pragana JP, Rosenthal S, Bragança IM, Silva C, Tekkaya AE, Martins PA (2020) Hybrid additive manufacturing of collector coins. Journal of Manufacturing and Materials Processing 4:115. https://doi.org/10.3390/jmmp4040115

    Article  Google Scholar 

  24. Bambach M, Sizova I, Sydow B, Hemes S, Meiners F (2020) Hybrid manufacturing of components from Ti-6Al-4V by metal forming and wire-arc additive manufacturing. J Mater Process Technol 282:116689. https://doi.org/10.1016/j.jmatprotec.2020.116689

    Article  Google Scholar 

  25. Pragana JPM, Sampaio RFV, Bragança IMF, Silva CMA, Martins PAF (2021) Hybrid metal additive manufacturing: a state–of–the-art review. Advances in Industrial and Manufacturing Engineering 2:100032. https://doi.org/10.1016/j.aime.2021.100032

    Article  Google Scholar 

  26. Almeida BPP, Alves ML, Rosa PAR, Brito AG, Martins PAF (2006) Expansion and reduction of thin-walled tubes using a die: experimental and theoretical investigation. Int J Mach Tools Manuf 46:1643–1652. https://doi.org/10.1016/j.ijmachtools.2005.08.018

    Article  Google Scholar 

  27. Pragana JPM, Bragança IMF, Silva CMA, Martins PAF. 2021. Revisiting the ring hoop test in additively manufactured metal tubes. Journal of Strain Analysis in Engineering Design (submitted).

  28. ASTM (2016) E8/E8M. Standard test methods for tension testing of metallic materials, ASTM International, West Conshohocken, USA

    Google Scholar 

  29. ASTM (2000) D2290-00. Standard test method for apparent hoop tensile strength of plastic or reinforced plastic pipe by split disk method, ASTM International, West Conshohocken, USA

    Google Scholar 

  30. Nielsen CV, Martins PAF (2021) Finite element simulation: a user’s perspective, In: Metal forming: formability, simulation and tool design. Academic Press, London. https://doi.org/10.1016/B978-0-323-85255-5.00011-X

  31. Hill R (1948) A theory of yielding and plastic flow of anisotropic metals. Proceedings of the Royal Society of London (Series A). 193:281–297

  32. McClintock FA (1968) A criterion for ductile fracture by the growth of holes. Journal of Applied Mechanics – Transactions ASME 35:363–371

    Article  Google Scholar 

  33. Cristino VA, Magrinho JP, Centeno G, Silva MB, Martins PAF (2019) A digital image correlation based methodology to characterize formability in tube forming. The Journal of Strain Analysis for Engineering Design 54:139–148. https://doi.org/10.1177/0309324718823629

    Article  Google Scholar 

  34. Martins PAF, Bay N, Tekkaya AE, Atkins AG (2014) Characterization of fracture loci in metal forming. Int J Mech Sci 83:112–123. https://doi.org/10.1016/j.ijmecsci.2014.04.003

    Article  Google Scholar 

Download references

Code availability

Not applicable.

Funding

The authors would like to acknowledge the support provided by Fundação para a Ciência e a Tecnologia of Portugal and IDMEC under LAETA- UIDB/50022/2020.

Author information

Authors and Affiliations

  1. IDMEC, Instituto Superior Técnico, Universidade de Lisboa, Lisbon, Portugal

    João PM Pragana, Carlos MA Silva & Paulo AF Martins

  2. CIMOSM, Instituto Superior de Engenharia de Lisboa, Instituto Politécnico de Lisboa, Lisbon, Portugal

    Ivo MF Bragança

Authors
  1. João PM Pragana
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Ivo MF Bragança
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Carlos MA Silva
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Paulo AF Martins
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Pragana JPM: Conceptualization, methodology, numerical modelling, experimentation, writing—editing. Bragança IMF: Conceptualization, investigation, methodology, visualization. Silva CMA: Conceptualization, investigation, methodology, visualization, supervision. Martins PAF: Conceptualization, funding acquisition, methodology, numerical modelling, supervision, writing—original draft.

Corresponding author

Correspondence to Paulo AF Martins.

Ethics declarations

Ethics approval

The article follows the guidelines of the Committee on Publication Ethics (COPE) and involves no studies on human or animal subjects.

Consent to participate

Not applicable.

Consent for publication

Not applicable.

Competing interests

The authors declare no competing interests.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Pragana, J.P., Bragança, I.M., Silva, C.M. et al. Integration of tube end forming in wire arc additive manufacturing: An experimental and numerical investigation. Int J Adv Manuf Technol 117, 2715–2726 (2021). https://doi.org/10.1007/s00170-021-07868-9

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-021-07868-9

Keywords

Search

Navigation