Effects of flow forming parameters on the development of residual stresses in Cr–Mo–V steel tubes

Tsivoulas, D.; Fonseca, João Quinta da; Tuffs, M.; Preuss, Michael

doi:10.1016/j.msea.2014.11.068

Cited by 22 publications

(16 citation statements)

References 21 publications

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“…Several parameters are involved in the flow forming process to achieve a component within dimensional tolerances, with a good surface finish and minimised tangential flow to prevent excessive thickness reduction [1]. These parameters are classified into five groups including process, working, tooling, machine and workpiece parameters [1]- [3].…”

Section: Introductionmentioning

confidence: 99%

“…One of the most important factors in flow forming is feed ratio, that is described as the ratio of the roller feed rate to the spindle speed [3]- [6]. Several studies [3]- [9] have been conducted on flow forming of different materials to form parts without defects and with homogenous microstructures. It was concluded that increasing or decreasing the feed ratio may result in the formation of various defects such as non-uniform thickness, reduction in diameter, rough surface, tearing, cracking (c) ASME.…”

Section: Introductionmentioning

confidence: 99%

“…with an increase in feed ratio, excessive material flow in an outward direction with a decrease in feed ratio [3].…”

Section: Introductionmentioning

confidence: 99%

“…In an investigation conducted by Roy et al [10], on the development of plastic deformation, it was shown that the local plastic strain increases faster at the roller interface compared to that of the mandrel interface, as the reduction in the thickness progresses with flow forming. These differential gradients in plastic deformation through the thickness may be one of the main sources of the generation of residual stresses [2], [3], [11]. Overall, a significantly high magnitude of residual stress is generated in the component.…”

Section: Introductionmentioning

confidence: 99%

“…In a recent study conducted by Tsivoulas et al [3], the generation of residual stresses during flow forming process of a Cr-Mo-V ferritic steel was investigated using XRD and neutron diffraction. In this approach, which was the first one in its kind, the influence of different parameters such as the level of wall thickness reduction, feed rate, and roller geometry on residual stresses was explored.…”

Section: Introductionmentioning

confidence: 99%

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Development of Process Induced Residual Stress During Flow Forming of Tubular 15-5 Martensitic Stainless Steel

Khayatzadeh

Moturu

Kelleher³

et al. 2017

Volume 6A: Materials and Fabrication

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Flow forming is a near net shape process for manufacturing of dimensionally accurate hollow components such as shaft in gas turbines, that is currently at its development stage for aerospace industry. The process has several advantages such as reducing material wastage, extremely fast manufacturing time, and eliminating extra manufacturing processes such as machining. Due to the nature of this complicated cold deformation process, significant magnitude of residual stress is introduced into the component. Understanding the magnitude and distribution of residual stress is essential to tailor the flow forming process to achieve parts within dimensional tolerances and desired mechanical properties. The present research is aiming to explore the generation and evolution of residual stress at various stages of flow forming process in a tubular component made from martensitic 15Cr-5Ni stainless steel, using different techniques of neutron scattering, x-ray diffraction (XRD) and hole-drilling based on electronic speckle pattern interferometry (ESPI).Residual stress measurements were carried out in preformed and flow formed components at surface, near-surface and in the bulk of components using XRD, ESPI based hole-drilling and neutron diffraction techniques. These measurements were conducted at different levels of reduction in the thickness of the original part (i.e. after 20% and 40%), by applying identical forming parameters for all samples. The XRD results show significant change in hoop and axial residual stress levels with a reduction in the wall thickness. This is more pronounced for the axial component where the average stress switches from relatively high tensile (~ 450MPa) in the original part to significant compressive stress (~ -600MPa) in the formed part, after 20% of reduction. The bulk residual stress components measured in the middle of thickness of the parts, using neutron scattering, show a general increase in the magnitude of residual stress by higher level of deformation (i.e. reduction in the wall thickness). The measured bulk stress components through the thickness were tuned to tensile after reducing the wall thickness by 40%. The results of XRD and neutron diffraction stress measurements suggest that the residual stress along the length of the samples (i.e. axial direction) is consistent with ±800 MPa and

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Section: Introductionmentioning

confidence: 99%