The possibility of forming parts by different methods is analyzed. The formation of defects is modeled and ways are proposed for eliminating them. A conclusion is reached as to the most efficient method of making the part that is discussed. Keywords: pneumo-thermal forming of sheetmetal parts, drop-hammer drawing, elastoforming, drawing in rigid dies.One of the most important problems in aeronautical and mechanical engineering is finding an efficient method for forming parts from flat-rolled products. The forming method is chosen on the basis of the experience and knowledge of the engineer, i.e., the effectiveness of the chosen solution depends on the human factor. Such dependence is unacceptable in modern industry. In this article, we will conduct a virtual search for an efficient manufacturing variant to make a part with the use of CAE systems.We chose a part ( Fig. 1) with a complex three-dimensional shape to analyze different forming methods. The double-curvature part contains two channels and two sides oriented in the same direction; the material of the part is alloy AMg6. The part's thickness is 0.8 mm.An efficient forming method will be sought in the PAM-STAMP 2G system developed by the French Company ESI Group to perform engineering analyses for sheet stamping.We will examine seven variants for forming the part. 1. Drawing out on a stamping hammer -the process most commonly used to make sheetmetal parts with a complex surface. The following assumptions were made during the modeling operation: a) the effect of deformation rate on stress is ignored; b) the end liners are modeled as having the properties of a material which can be described by the Mooney-Rivlin model; c) the end of impact is determined by the limit on the travel of the punch; d) the plastic part of the flow curve is expressed through the function in the Krupkowsky law (σ = K(ε 0 + ε p ) n , where σ is the running level of stress; K is the strength coefficient; ε 0 and ε p are the initial and running levels of plastic strain; and n is the strain-hardening coefficient); e) Hill model 48 is chosen to describe the yield surface; and f) the initial thickness of the semifinished product is 1 mm.
An alternative method is described for making tees. The article discusses the main stages in the advancedParts called "tees" are commonly used in the systems of conduits in aircraft to separate flows of liquid or gas into two flows or to combine two such flows (Fig. 1).To make such parts, a drop hammer or a rigid die is used to divide a flanged pipe into two symmetrical halves which are then welded. This standard tee-forming technology has several shortcomings: 1) a significant amount of material is lost because of the established tolerances; 2) the finishing operations, involving the stamping and welded of a flanged pipe, are labor-intensive; and 3) it is necessary to use several different types of equipment. Metallurgist, Vol. 56, Nos. 11-12, March, 2013 (Russian Original Nos. 11-12, Nov.-Dec., 2012
FORMING OF TEE PARTS BY A PROCESS THAT COMBINES DIFFUSION WELDING AND PNEUMOTHERMAL FORMING IN THE SUPERPLASTIC REGIME
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