Flow forming optimization based on diametral growth using finite element method and response surface methodology

Aghchai, Abdolhossein Jalali; Razani, N. A.; Dariani, Bijan Mollaei

doi:10.1177/0954405412461328

Cited by 18 publications

(7 citation statements)

References 21 publications

(26 reference statements)

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“…Previous studies mainly focused on the processing parameters of traditional power spinning (Bhatt et al, 2017;Wang et al, 2020;Jalali et al, 2012). (Xiao et al, 2014) established the metal flow model during CRS and derived the calculation formula of equivalent strains of the spun parts on the basis of the upper bound method.…”

Section: Influence Of Process Parameters On the Forming Results Of Large-sized Cylindrical Parts During Counter-roller Spinning 1 Introdumentioning

confidence: 99%

Influence of process parameters on the forming results of large-sized cylindrical parts during counter-roller spinning

Zhao

Zhu

et al. 2022

JAMDSM

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As an advanced plastic-forming method, counter-roller spinning (CRS) is mainly applied to process large-sized, thin-walled cylinder for aerospace rocket engine. Medium carbon quenched and tempered steel 30CrMnSiA is a typical material for solid rocket motor due to its high strength, high toughness and good fatigue resistance. The determination of complex process parameters and the detection of multiple forming indexes are necessary for the study of CRS. In this paper, a finite element (FE) model for CRS of 30CrMnSiA cylinder with a diameter of 2.25 m was established and verified according to the experimental data. The effects of multiple process parameters on the forming results were studied and analyzed by orthogonal experiment. Results reveal that the thinning ratio is the most important process parameter for all the forming results. Larger thinning rate can improve production efficiency but reduce forming accuracy and require equipment to provide greater spinning force. The influence laws of process parameters on the forming accuracy and spinning force of the outside of the cylindrical parts are similar to that of the inside of the cylindrical parts. In addition, the forming accuracy error and spinning force of the inside of the cylindrical parts are smaller than that of the outside of the cylindrical parts. Thus, the forming force and positioning accuracy of the outer roller holder can be given priority when developing the CRS equipment. Based on the ANOVA results, a multivariate nonlinear regression analysis was performed on the forming results by selecting significant process parameters as independent variables. The optimal range of process parameters for obtaining good forming results was obtained by processing the regression equation.

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Section: Influence Of Process Parameters On the Forming Results Of Large-sized Cylindrical Parts During Counter-roller Spinning 1 Introdumentioning

confidence: 99%

Influence of process parameters on the forming results of large-sized cylindrical parts during counter-roller spinning

Zhao

Zhu

et al. 2022

JAMDSM

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“…[19] develop a characterization of the process through the use of a particular classic DoE design (Box-Behnken), which is strictly related with RSM (response surface methodology) evaluation of the results. [20] use fractional factorial DoE and graphical methods (RSM) in order to characterize the variables of their model for steel. The authors propose and optimize a set of variables, which are built by simulation trials of validation.…”

Section: Investigative Methodologiesmentioning

confidence: 99%

A Review of Flow Forming Processes and Mechanisms

Marini

Cunningham²,

Corney

2015

KEM

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Abstract. After years of purely academic interest and niche applications, today the flow forming process is increasing demand in aerospace, automotive and defense industries. This review surveys academic paper of last fifty years, in order to evaluate the current state-of-the-art for academic and practitioner. Theoretical and experimental approaches are collected and compared by evaluating their prediction models. As a result, several knowledge gaps are identified, for example stress and strain tensors evolutions are not determined for workpiece, due to high computational cost and uncertainty about the correct finite elements approach to adopt. Similarly although, the final microstructure is often evaluated for specific cases, study of its evolution during plastic deformation has not been reported. Residual stress and final material proprieties, such as corrosion behavior, have been not studied numerically or experimentally. Tool path impact and alternative geometries are not deeply explored. Particular attention is given to process experimental optimization and characterization through Design of Experiment, which is still limited to a few papers and sometimes not well developed. The results of this review will help define a research agenda for future developments.

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“…Results of ANOVA analysis confirm roller tip radius as most crucial parameter effective tube surface finish followed by thickness reduction ratio. Aghchai et al [48] [49] have used Taguchi method for optimization of inner rib thickness during simulation of the neck-in process of the AA6061-T6 alloy. They have used mandrel support span, mandrel speed, feed rate and roller diameter as input/control variable and adopted S/N ratio, response chart and average response chart method for optimization of the inner rib.…”

Section: Modelling Of the Process Using The Design Of Experiments (Domentioning

confidence: 99%

Flow forming of thin-walled precision shells

et al. 2018

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Flow forming is an innovative form of cold and chipless metal forming process, used for the production of high precision, thin-walled, net-shaped cylindrical components. During this process, the length of a thick walled tube, commonly known as a preform, is increased with a simultaneous decrease in the thickness of the preform without any change in the internal diameter. Forming of the preform is carried out with the help of one or more rollers over a rotating mandrel. By a predetermined amount of thickness reduction in one or more number of forming passes, the work material is plastically deformed in the radial direction by compression and made to flow in an axial direction. The desired geometry of the workpiece is achieved when the outer diameter and the wall of the preform are decreased, and the available material volume is forced to flow longitudinally over the mandrel. Over the last three and a half decades the flow forming technology has undergone several remarkable advancements. The versatility of the process makes it possible to produce a wide variety of axisymmetric, nearer to the net-shape tubular parts with a complex profile using minimum tooling changes. In this review article, process details of flow forming have been elaborated. The current state-of-the-art process has been described, and future developments regarding research and industrial applications are also reviewed.

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Flow forming optimization based on diametral growth using finite element method and response surface methodology

Cited by 18 publications

References 21 publications

Influence of process parameters on the forming results of large-sized cylindrical parts during counter-roller spinning

Influence of process parameters on the forming results of large-sized cylindrical parts during counter-roller spinning

A Review of Flow Forming Processes and Mechanisms

Flow forming of thin-walled precision shells

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