Simulation-enabled study of folding defect formation and avoidance in axisymmetrical flanged components

Chan, Wai Ming; Fu, Ming; Lu, Jincheng; Chan, Luen Chow

doi:10.1016/j.jmatprotec.2009.02.005

Cited by 57 publications

(11 citation statements)

References 18 publications

(17 reference statements)

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“…FE simulation was widely used to analyze the forming characteristics and defects in metal forming, since it can provide a researcher with various forming knowledge such as distribution of stress, strain and velocity, and the evolution of defects (folding, underfilling, flow line disturbance, etc.) during forming process [16][17][18][19][20]. So, FE simulation was also applied to study the forming characteristics and defects of transitional region in the present work.…”

Section: Physical Experiments and Its Fe Simulationmentioning

confidence: 99%

Forming defects control in transitional region during isothermal local loading of Ti-alloy rib-web component

Gao

Yang

Fan

et al. 2014

Int J Adv Manuf Technol

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The forming quality of transitional region plays a key role in the performance of titanium alloy large-scale ribweb component under isothermal local loading forming. In this work, a local eigen model of transitional region in the local loading forming of large-scale rib-web component is extracted so as to catch the detail-forming characteristics of transitional region with low computation time in simulation and experiment cost. Then, based on the local eigen model, the mechanism of forming defects in transitional region and their dependence on processing parameters are studied by the combination of physical experiment and verified finite element (FE) simulation. It is found that the second loading step can be divided into two forming stages according to the material flow pattern: (1) the transverse flow stage and (2) the stable forming stage. In the transverse flow stage, there exists long-range transverse flow of web material and excessive transverse flow would lead to the formation of folding and cavum defects. Moreover, the severities of defects are well correlated with the quantity of material transferred into the first-loading region in this stage. For a certain reduction amount, decreasing spacer block thickness and increasing friction both can decrease the quantity of transferred material and then suppress the development of folding and cavum defects, while the deformation temperature and loading speed have little effect on the quantity of transferred material and defects. In the end, an effective way is put forward to suppress and prevent the defects in transitional region during the local loading forming of titanium alloy large-scale rib-web component.

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Section: Physical Experiments and Its Fe Simulationmentioning

confidence: 99%

Forming defects control in transitional region during isothermal local loading of Ti-alloy rib-web component

Gao

Yang

Fan

et al. 2014

Int J Adv Manuf Technol

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“…Molitnikov et al [17] studied the deep drawing process considering the blank thickness and discovered that the size effect can be influenced by the ratio of grain size and the blank thickness in this process. Chan et al [18] further investigated the size effect on the forging of flanged components and developed a systematic design approach for predicting and avoiding folding defects. Then Chan et al [19] studied the manufacturing of meso-scaled flanged parts and cylindrical bulk.…”

Section: Introductionmentioning

confidence: 99%

Study on size-related product quality of multiscale central-punched cups fabricated by compound forming directly using brass sheet

Zheng

2022

Int J Adv Manuf Technol

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Meso/microforming has gained much more attention in the last decades and is widely used as a reliable method to fabricate meso/micro-scaled metallic components.In this research, a compound meso/microforming system which combines deep drawing, punching and blanking operations was developed to fabricate multiscale central-punched cups by using brass sheets. The parts with three scales were produced by using the brass sheets with various thicknesses and grain sizes to investigate geometrical and grain size effects on the deformation behaviors, dimensional accuracy, and material flow behaviors in the forming process. Through physical experiments and finite element simulations, it is revealed that the ultimate deformation load in the drawing-punching stage is smaller than that in the single deep drawing stage under microscale, but the results in the meso-scaled scenarios are opposite. In addition, the thickness variation is increased with grain size, but the variation of the normalized thickness variation does not show an obvious tendency with different size scales. In the bending area, the material flow is tangential to the thickness direction, leading to the formation of thinning area. In addition, the material flow is almost opposite to the punching direction in the punching area, avoiding the expanding deformation of the hole. Thus, the punching operation barely affects the dimensional accuracy including the thickness and hole diameter of the formed parts.Furthermore, the micro-scaled cups with finer grains have a better surface quality.These findings enhance the understanding of size effect in compound meso/microforming with the combined deep drawing and punching operations.

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“…Therefore, to obtain the desired properties, it is necessary to carefully design the process to yield the required microstructure distribution in the final product. Traditionally, process design in the context of hot forging has majorly been limited to address issues such as die designing [1,2], reducing underfill [3], avoiding possible defects [4][5][6], flash design [7][8][9], forging load [10][11][12] and more recently microstructure evolution [13][14][15][16][17]. Often, these approaches focus primarily on the deformation sub-step design without paying much attention on the role of the process in the larger product development workflow which includes material selection, other upstream and downstream processes and final property requirement.…”

Section: Introductionmentioning

confidence: 99%

Integrated modelling of hot forging of low-alloyed steels for an ICME workflow

2019

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One of the key aspects of integrated computational materials engineering approach is the integrated modelling of process chains that capture the essential microstructure physics and predict the final properties. In the current work, such an integrated modelling approach is attempted for analyzing the hot forging process for low-alloyed steels. Traditionally, hot forging process is designed with primary focus on the deformation step, with less attention paid to the incorporation of microstructure information flow between its sub-steps of heating, deformation and cooling. Such a siloed approach restricts its integration with other manufacturing processes, and also with design and material selection stages. To address the issue, in this work, a FEM based thermo-mechanical modelling framework, integrating composition dependent microstructure evolution models for heating, deformation and cooling sub-steps, is implemented for hot forging of low-alloyed steels. The evolution of key microstructural features at each sub-step is tracked and fed to the following step. The integrated modelling framework is then used to study the effect of process parameters and macrosegregation in the billet on the distribution of final microstructure and properties obtained for a sample steel upsetting process. Key observations made in the studies are discussed. Ways of representation of the distribution of microstructure and properties across the forged part, that can enable better decision making in the larger perspective of downstream processing and final use, are highlighted. Consequently, the utility of the integrated modelling approach to aid the development of improved process and product design capabilities for hot forged products is established.

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Simulation-enabled study of folding defect formation and avoidance in axisymmetrical flanged components

Cited by 57 publications

References 18 publications

Forming defects control in transitional region during isothermal local loading of Ti-alloy rib-web component

Forming defects control in transitional region during isothermal local loading of Ti-alloy rib-web component

Study on size-related product quality of multiscale central-punched cups fabricated by compound forming directly using brass sheet

Integrated modelling of hot forging of low-alloyed steels for an ICME workflow

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