A methodology for assessing the feasibility of producing components by flow forming

Abstract

This paper describes a methodology for assessing the applicability of the flow forming process for the manufacture of specific components. The process starts by filtering potential candidates for flow forming from a component collection and then carries out a detailed assessment of quantitative, technological and economic feasibility before determining a viable process plan. The process described uses analytical relationships and criteria drawn from the literature. For example, qualitative feasibility is evaluated using analytical relationships for ultimate strength prediction. Similarly technological validation is done estimating forming process forces and defects rate which are evaluated against threshold values. A process time model is used to develop a hybrid cost model in order to evaluate economic feasibility. Using these calculated values production feasibilities are established by comparison with reported reduction ratios and process parameters. The paper concluded with a brief summary of the results of applying the process to an industrial case study

Innovative Online Measurement and Modelling Approach for Property-Controlled Flow Forming Processes

“…In [12], Riepold et al already proposed a system model for the forming process of metastable austenitic steels which is based on a geometrical modelling approach by Marini et. al [13]. Riepold et al use an ideal deformation model and an analytical model of the martensite transformation.…”

“…The material flow in axial direction is a direct consequence from plastic deformation in radial direction. Here the approach of volume constancy according to [12] and [13] is used. Comparing the volume of the hollow frustrum (described by surface line and the discrete points) before and after forming, the elongation of the volume element (length 𝑙𝑙 𝑖𝑖 ) is described by…”

“…In the model, the forming parts are locally discretized in 𝑛𝑛 − 1 hollow conical frustums, like the approaches in [12] and [13]. Due to the assumed axial symmetry, these parts and frustums are clearly described by its surface line (see Fig.…”