Finite-element modelling of a novel flanging process on a cylinder with a large diameter–thickness ratio

Fan, Shuqin; Zhao, Shengdun; Zhang, Q; Wang, C H

doi:10.1177/2041297510393627

Cited by 6 publications

(5 citation statements)

References 20 publications

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“…The 180° and 270° direction wall thickness was the largest, while the smallest appeared in the 0° and 90° direction. The distribution pattern of the wall thickness was consistent with that reported in Fan et al 17 The reason for this phenomenon is that the material thinned and displaced in the direction opposite to the motion of the roller (backward tube spinning), since the rotating was through 180°. Hence, wall thickness was greater in the region from 180° to 270°, when compared to that from 0° to 90°.…”

Section: Simulation Results and Discussionsupporting

confidence: 89%

“…It can be observed that the design of the roller path plays a decisive role for parts with complex geometric features. A novel flanging process on a cylinder with a large diameter-thickness ratio was simulated by Fan et al 17 through FEM. Xiao et al 18 studied the non-axisymmetric multi-pass rotation characteristics of the oblique flange cylinder.…”

Section: Introductionmentioning

confidence: 99%

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Numerical simulation study on multi-pass non-axisymmetric spinning of cylindrical parts with oblique flange

Zhang

Han

et al. 2019

Proceedings of the Institution of Mechanical Engineers, Part B:

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A non-axisymmetric cylinder with an oblique flange has broad application prospects. Spinning is the main production process for this kind of workpiece. Finite element modeling is a necessary method to study some key problems that are difficult to be solved merely through experiments, such as the strain and stress fields in the development of this spinning technology. In this study, the spinning process of a non-axisymmetric oblique flange cylindrical part was established and simulated using ABAQUS/explicit software. The credibility of the simulation result was validated through an experiment. The influence of the axial roller feed along the cylinder wall on the distribution of wall thickness and stress and strain during the forming process was analyzed. The change in stress field and strain field with time was analyzed, and the quantitative relationship between forming conditions and forming results was described. Furthermore, the forming principle of the flange was analyzed. It would be beneficial for flange forming to reduce the increasing distance of the cylinder wall in the 180° direction (parameter c) and the vertical distance from the closest point to the spindle as the roller returns back in the 180° direction (parameter d), to a certain extent. Hence, a workpiece with an ideal appearance was obtained. By comparing the wall thickness distribution, the design and optimization of the roller path were once again verified to be reasonable.

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Section: Simulation Results and Discussionsupporting

confidence: 89%

Section: Introductionmentioning

confidence: 99%

Numerical simulation study on multi-pass non-axisymmetric spinning of cylindrical parts with oblique flange

Zhang

Han

et al. 2019

Proceedings of the Institution of Mechanical Engineers, Part B:

View full text Add to dashboard Cite

show abstract

“…Total procedure of forming the tube into dome is simulated. Generally, researchers like Fan et al, 15 Huang et al, 12 and Lexian and Dariani 10 have used shell elements to model spinning processes because of long computation times of the models with solid elements. In this study, cubic solid elements are used to preserve the stress and strain variation in thickness.…”

Section: Fe Simulationmentioning

confidence: 99%

Finite element study of stress and strain state during hot tube necking process

Zoghi

Arezoodar

2013

Proceedings of the Institution of Mechanical Engineers, Part B:

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Tube necking is a common process used for manufacturing pressure vessels, for example, compressed natural gas capsules, categorized under general spinning processes. An experimentally validated finite element model suited to the process is incorporated to study the deformation, and state of strain and stress in the contact zone. The in situ variation of stress and strain is illustrated via colored contour plots, and Cartesian and polar diagrams. It is shown that in some areas, there are similarities and differences between flow forming and tube necking; for example, like flow forming, the equivalent plastic strain decreases from the inner and outer layers toward the middle layer, and unlike flow forming, the axial strain at the outer layer is negative all around the tube while at the inner layer, axial strain possesses a maximum positive value at contact position. The state of stress and plastic strain in regions around the contact zone is shown at an instant of process duration, which is not quite similar to postprocess stress and strain distribution.

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“…The process is categorized as one of the various spinning procedures in which there is no mandrel or die. Some recent articles on general spinning and flow forming processes include the works of Razani et al 1 on the experimental study of flow forming of steel tubes, Wang et al 2 on the study of the effect of roller feed on wrinkling in conventional spinning and works of Fan et al 3 on the investigation of a novel flanging method by spinning.…”

Section: Introductionmentioning

confidence: 99%

Effect of feed and roller contact start point on strain and residual stress distribution in dome forming of steel tube by spinning at an elevated temperature

Zoghi

Arezoodar

Sayeaftabi

2012

Proceedings of the Institution of Mechanical Engineers, Part B:

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Tube spinning, without mandrel, is a common process used for manufacturing pressure vessels, e.g. CNG (Compressed Natural Gas) capsules for automotive industry and fire extinguishers. The process is carried out at an elevated temperature for forming a dome on thick wall steel tube ends. Two of the most important control parameters in the process are the “roller contact start point” (RCSP) and spinning feed (pitch), both of them highly affecting the process time and deformation behavior of the tubes and therefore success and quality of the product. In this article, using a three-dimensional dynamic explicit finite element model, the effects of these parameters are investigated on circumferential, axial and radial (thickness) strains of the formed tube in three thickness layers of the tube wall. The model is also verified by experiment. While circumferential strain is shown to be independent of the feed, axial and thickness strains are highly affected by both the feed and roller contact start point. It is shown that when the roller contact start point distance from the free end of the tube increases, there is a risk of indentation instead of normal bending behavior. It is also shown that axial strain has an inverse relation with feed, i.e. decreasing the feed results in further elongation of the tube. On the other hand, thickness strain increases by increasing the feed, so bigger thicknesses are expected in domes manufactured by higher feeds. In addition, it is shown that increasing the feed results in a decrease of the equivalent strain. The amount of residual stress (regardless of the temperature change) increases with increasing feed and its distribution is more uniform for higher distances of the contact start point from the free end.

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Finite-element modelling of a novel flanging process on a cylinder with a large diameter–thickness ratio

Cited by 6 publications

References 20 publications

Numerical simulation study on multi-pass non-axisymmetric spinning of cylindrical parts with oblique flange

Numerical simulation study on multi-pass non-axisymmetric spinning of cylindrical parts with oblique flange

Finite element study of stress and strain state during hot tube necking process

Effect of feed and roller contact start point on strain and residual stress distribution in dome forming of steel tube by spinning at an elevated temperature

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