Numerical and Experimental Forming of Axisymmetric Products Using Methods of Deep Drawing and Flow Forming / Numeryczne I Eksperymentalne Kształtowanie Wyrobów Osiowosymetrycznych Metodą Tłoczenia Oraz Kształtowania Obrotowego

Abstract

The growing demand for products with higher durability and quality of performance affects the need for new technologies and for new methods of analysis of the correctness of their performance at the design stage [1][2][3]. Continuous progress in the field of rotary plastic forming methods affects, inter alia, the classification of technological processes. More and more often used technique of forming of axisymmetric products is rotary forming which includes metal spinning, flow forming and hybrid forming. The rotary forming processes is classified among stamping, however, the forces encountered during spinning and flow forming are much smaller due to the local contact of tools with shaped material [4,5]. The most important difference between the metal spinning and the flow forming concerns the product wall thickness. In spinning process, the thickness remains the same, while in the flow forming it is intentionally reduced. Rotary forming can be performed in the cold and hot state. Material deformation in the process of metal spinning is influenced by many factors [6][7][8]. The most important are:• rotational speed of the mandrel• working roller travel • working radius of the roller • diameter of the metal spinning rollerThe use of modern computer technology has become an integral part of the development of innovative stamping, spinning and flow forming technologies. The application of numerical analysis systems based on the finite element method speeds up the design and optimization of forming processes. However, the use of computer simulation systems with GUI for analysis of rotary forming is complicated, mainly due to the lack of a commercial software dedicated to such processes and equipped with system of process automation. An increasing number of manually operated numerical analyzes of the rotary forming process shows how important is that method of metal forming [9,10] in the context of industrial processes.The basis of the analysis were tests carried out in Metal Forming Institute in Poznan. The test material, a Hastelloy C-276 (UNS N10276) alloy, was subjected to stamping and subsequent The paper deals with the problem of forming of axisymmetric element. Two-stages process was taken into consideration: deep drawing of metal blank using hydraulic press and the method of elongating flow forming. The contribution presents results of numerical and experimental analyzes. numerical simulations of both the processes were realized in kraków at aGH University. Numerical verification of both processes was carried out using finite element models implemented with the help of commercial analysis system on basis of conducted in Poznań experimental shaping tests of Hastelloy c-276 alloy. The tests were aimed to find opportunities and conditions of plastic deformation of the material. This article summarizes example results of both numerical and experimental forming of products made of hard-to-deform material..