The friction caused power losses and bulging deformation are always inevitable. The rotating compression forming can reduce the compression force and bulging deformation in metal forming. Furthermore, the bounded double-layer metal material is able to have advantage in proper material cost saving and meeting the required strength for customer. Accordingly, this present study proposes the analysis based on Slab Method (SM) and Finite Element Method (FEM) under constant shear friction to predict the compression force and the rotating moment in the rotating compression forming. Moreover the bulging deformation profiles, the effective stress, the effective strain, the velocity field, the compression force, the rotating moment, and the twist angle can be obtained from FEM simulations. It is also shown that the predicted results have the same trend to verify the acceptance of analysis models.
Bulging deformation during cylinder compression forming results in geometrical imprecision and flow stress prediction error. Consequently, the present study proposes a hybrid technique comprising the Upper Bound Method (UBM) and geometrical fitting method. It is noted that a volume conservation constraint and an elliptical curve-fitting method with UBM for predicting both the compression force and the bulge profile. It is shown that the predicted results for the compression force based on UBM under certain reduction ratios of 30%, 40%, 50% and 60% are in good agreement with those obtained by experiment, Finite Element Method (FEM), and Slab Method (SM). In addition, it is revealed that the use of an elliptical curve-fitting technique provides a reasonable approximation of the bulge profile obtained by experiment and FEM simulations. Generally, the proposed method effectively provides a low-cost, computationally straightforward means of estimating the compression force and bulge profile in cylinder compression forming. Therefore it can be utilized as the widespread applications in the metal forming field.
The objective of this study is to establish three analytical models including the Upper Bound Method (UBM), the Slab Method (SM), and the Finite Element Method (FEM) for the rotating compression of bonded double-layer clad cylinder. As for the prediction of bulging deformation, apart from the FEM simulation, the other hybrid method can combine the UBM with an elliptical curve-fitting method for predicting compression force and bulging deformation. Meanwhile, the compression force and bulging deformation between analyses and experiment are compared to validate the correctness of the models. These models established can be offered to the reference of metal forming industries.
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