Abstract
In this study, we design an integrated manufacturing process for Al6061 alloy bolts to fasten offshore platforms. The proposed scheme includes the theoretical design and numerical study for the heading, trimming, and thread-rolling process. For the theoretical design, the initial rod diameter and the penetration depth (PD) in the thread-rolling process are calculated according to thread standards and geometric relation. The dimensions of the initial workpiece for the heading process are obtained using the volume constancy law. Considering process limitations to predict the defects, the number of stages is set, and the preform is then determined using the design rule in the heading process. Based on the theoretical design, finite-element (FE)-analysis is conducted. In order to predict the defects and fracture phenomena, the ductile fracture criterion was applied during the heading and trimming processes. The Taguchi method is used to optimize the trimming and thread-rolling process with the set of design parameters, such as the PD, transfer velocity, and revolutions per minute in the thread-rolling process, and the blade radius (BR), land width, and stop distance in the trimming process, respectively. Results show that the PD and BR have the most significant effect on the dimensional accuracy and forming load. To validate the proposed design, the aluminum alloy bolt-forming experiment is performed. We obtain the sound Al6061 alloy M12 hexagonal bolt shaped with highdimensional accuracy. Therefore, this research provides valuable guidelines for the design of the integrated forming process in actual bolt production.
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This work was supported by the National Research Foundation of Korea (NRF) grant funded by the Korea government (MSIP; Ministry of Science, ICT & Future Planning) (No. 2017R1C1 B5017016).
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Recommended by Guest Editor Maenghyo Cho.
Sung-Cheol Park received his B.S. degree (2014) from Korea Maritime and Ocean University in Korea. Mr. Park is currently getting a master's degree at Division of Marine Engineering in Korea Maritime and Ocean University in Korea. His major research field is metal forming technologies including forging and thread-rolling.
Dong-Hoon Lee received his M.S. degree (2003) from Pusan National University in Korea. Mr. Lee is currently a Department Head in S&T Motive. His major research field is metal forming technologies including cold/hot forging and stamping.
Kyung-Hun Lee received his Ph.D. (2013) from Pusan National University in Korea. Dr. Lee is currently an Assistant Professor at Division of Marine Engineering in Korea Maritime and Ocean University in Korea. His major research field is metal forming technologies including wire and shape drawing, rolling, shape rolling, ring rolling, and cold/hot forging process.
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Park, SC., Lee, DH., Ko, DC. et al. Integrated process design of Al6061 alloy bolts for fastening offshore platforms. J Mech Sci Technol 33, 3695–3707 (2019). https://doi.org/10.1007/s12206-019-0711-5
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DOI: https://doi.org/10.1007/s12206-019-0711-5