Comparison between rotary and conventional flaring processes

Tamang, Subha; Bylya, Olga I.; Ward, Michael J.; Luo, Xichun; Halliday, Steven; Tuffs, M.

doi:10.1063/1.5008047

Cited by 4 publications

(5 citation statements)

References 8 publications

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“…Fillets of 1.5mm radius were machined on both edges at the top end (forming end) of the workpiece to ensure smooth initial contact with the top tool. A 55° (β) top tool was used as it affords possibility for nutation of 35° to the horizontal datum and thereby high flexibility without compromising on the strength of the tool (Tamang et al 2017). A hollow bottom tool with a cylindrical cavity of a depth of 75 mm, maximum clearance of 0.1 mm with the O.D.…”

Section: Methodsmentioning

confidence: 99%

“…Hence, RT material data was deemed to be representative enough. The detailed modelling methodology used and the challenges faced in modelling rotary forming processes are summarised in earlier works [ (Krishnamurthy et al 2017;Tamang et al 2017;].…”

Section: Forming Methodsmentioning

confidence: 99%

“…This in turn renders the design for the processing and shaping of tool kinematics a significant challenge. Previous studies in this area are limited [ (Tamang et al 2017;Montoya et al 2008;Oudin et al 1985;Appleton and Slater 1973)] and stock commercial finite element software packages are not well suited to model this process, due in large part to the big uncertainty in having an appropriate material model and assumptions on boundary conditions.…”

Section: Figure 1 Representation Of the (A) Versatile Range Of Compon...mentioning

confidence: 99%

“…Rotary forming is an incremental bulk forming process that affords the possibility to form a wide range of tubular components using simple sets of tools prescribing a complex tool path [ (Groche et al 2007), (Tamang et al 2017)]. The high degrees of freedom (DoF) and highly localised area of deformation makes it a very flexible process.…”

Section: Introductionmentioning

confidence: 99%

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Instability Analysis in Incremental Rotary Forming of Tube Flanges

et al. 2021

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Rotary forming is an exciting route for forming flanges of different angles from seamless tubes of high-strength materials. True to its incremental nature, the process offers great flexibility, but the issues encountered are atypical and complex. One such issue observed in experimental trials is the internal buckling of tubes during specific instances of flange formation. The origin of this instability is non-trivial, and ordinarily, finite-element (FE) models fail to capture this instability. To analyse and understand the problem, systematic experimental trials were carried out using different tube thicknesses, tube materials and tool kinematics. This paper summarises the results from a critical analysis to establish (1) a criteria for quantifying the instability and identifying the instances of its occurrence, (2) a validation methodology to fine-tune FE models for the process, and (3) use of FE models to understand the influence of tool path in the flange forming stage.

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Section: Methodsmentioning

confidence: 99%

Section: Forming Methodsmentioning

confidence: 99%

Section: Figure 1 Representation Of the (A) Versatile Range Of Compon...mentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Instability Analysis in Incremental Rotary Forming of Tube Flanges

et al. 2021

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“…[5] Rotary forming is one of the promising incremental processes. The comparison between rotary forming and conventional flaring was investigated [6] a rotating tool on its flaring axis and performed experiments to analyze the expansion ratio, strain path, and failure limit. Several trials of tube end forming at varing rotational speeds and compared with other conventional flaring techniques.…”

Section: Introductionmentioning

confidence: 99%

A Numerical Study on Conventional Tube Flaring Process

Singh

Brar

Kumar

2022

Advances in Transdisciplinary Engineering

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Tube flaring process involves a conical tool of a certain length which is displaced to get an end flared tube, which is utilized to form a tight seal between pipes or tubes. Tube flaring refers to a kind of forging which is often a cold working operation. The tube forming process is widely used in several industries to form condenser pipes, car seat structures, exhaust piping, etc. Thin-walled tubes were used in automobiles to reduce the total weight for better performance. A conical tool is used for tube end forming in which the tool is moved into the tube known as conventional tube flaring. In this work, a numerical study was directed using FEA software ANSYS/Implicit which is used to analyze the stress conditions involved in tube flaring. Here, the tool is considered rigid and displaced by using displacement control by 25 mm, and other parameters were studied at this displacement. Effects of different semi-cone angles were also considered for the study.

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