Tube/tube joining technology by using rotary swaging forming method

Zhang, Qi; Jin, Kaiqiang; Dong, Mengyao

doi:10.1016/j.jmatprotec.2014.02.002

Cited by 52 publications

(18 citation statements)

References 17 publications

Supporting

Mentioning

Contrasting

Unclassified

Order By: Relevance

“…Therefore, it can be ensured that the force that the blank tube bears is more uniform, and the organization of the blank tube is more consistent. 20 In this article, the schematic view of the rotary swaging of the steering column is shown in Figure 2. During rotary swaging, the ambient temperature of the blank is approximately 38°C.…”

Section: Optimum Problem Descriptionmentioning

confidence: 99%

Mechanical properties optimization of the steering column based on multi-objective optimization design

Chen

Wang

Lv³

2016

Advances in Mechanical Engineering

View full text Add to dashboard Cite

The mechanical properties of the steering column have a significant influence on the comfort and stability of a vehicle. In order for the mechanical properties to be improved, the rotary swaging process of the steering column is studied in this article. The process parameters, including axial feed rate, hammerhead speed, and hammerhead radial reduction, are systematically analyzed and optimized based on a multi-objective optimization design. The response surface methodology and the genetic algorithm are employed for optimal process parameters to be obtained. The maximum damage value, the maximum forming load, and the equivalent strain difference obtained with the optimal process parameters are, respectively, decreased by 30.09%, 7.44%, and 57.29% compared to the initial results. The comparative results present that the quality of the steering column is improved. The torque experiments and fatigue experiments are conducted with the optimal steering column. The maximum torque is measured to be 260 NM, and the service life is measured to be 2 weeks (40 NM, 2500 times), which are, respectively, increased by 8.3% and 8.69% compared to the initial results. The above results display that the mechanical properties of the steering column are optimized to verify the feasibility of the multi-objective optimization method.

show abstract

Section: Optimum Problem Descriptionmentioning

confidence: 99%

Mechanical properties optimization of the steering column based on multi-objective optimization design

Chen

Wang

Lv³

2016

Advances in Mechanical Engineering

View full text Add to dashboard Cite

show abstract

“…Numerical analysis of the ICFP was conducted using the Forge 3D software [10][11][12], based on the FEM. Geometric model of the forming process is presented in Figure 3.…”

Section: Finite Element Modelmentioning

confidence: 99%

Research on Integrated Casting and Forging Process of Aluminum Automobile Wheel

Zhang

Cao

Zhang

et al. 2014

Advances in Mechanical Engineering

Self Cite

View full text Add to dashboard Cite

Integrated casting and forging process (ICFP) is a new manufacturing method combining the advantages of both casting and forging. Aluminum structure parts, such as aluminum alloy automobile wheel, with complex shape and excellent mechanical properties can be produced by this process. The effects of different process parameters on the ICFP of the automobile wheel were simulated by Forge software. Microstructure of forging region and the nonforging region were studied by experiment. The results show that die temperature, static pressure of the injection piston, forging speed, and material flow have significant influences on the process. Compared with nonforging region, the microstructure of forging region becomes finer, more uniform, and denser. Meanwhile, the casting defects can be removed and mechanical properties improved.

show abstract

“…For example, Alkhazraji et al found that both tensile and fatigue strength are enhanced in workpieces with ultra-fine grains made by rotary swaging [Alk15]. The process was also analyzed for joining tubes [Zha14] or for plating axisymmetric metallic parts [Sch16]. With regard to high productivity in the micro range, infeed rotary swaging can already facilitate several hundred parts per minute by a continuous process, for example as a preliminary stage for extrusion [Ish18].…”

Section: Introductionmentioning

confidence: 99%

Micro Forming Processes

Kuhfuß¹,

Schattmann

Jahn

et al. 2019

Lecture Notes in Production Engineering

View full text Add to dashboard Cite

The projects of this chapter describe micro forming processes that are studied as single processes but can also be combined as process chains. Proven examples are material accumulation and succeeding rotary swaging, or rotary swaging and extrusion.Micro forming differs from macro forming due to scaling effects, which can mean both challenges and benefits. Problems may arise from the handling of fragile parts or adhesive forces between the micro parts or friction effects.Benefits from scaling effects are made use of in the project "Generation of functional parts of a component by laser-based free-form heading". The aim is a material accumulation that is generated from short duration laser melting. This material accumulation gives the basis for succeeding cold forming operations. The first powerful application for the new technology was upsetting. In the macro range, upset ratios of about 2.3 are achievable, but this is reduced in the micro scale due to earlier buckling of the components. In the micro scale, where cohesive forces can exceed the gravitational force, the molten material forms a droplet that remains adhered to the rod. Thus, upset ratios of up to 500 were reached. The process development was accompanied by a mathematical model and allows for a deep insight into the thermodynamics of laser-induced material accumulation in the micro range.The laser molten material accumulation could, for example, be further processed by micro rotary swaging. Though rotary swaging has been known in the macro range for a long time and is nowadays an intensively used process in the automotive industry to produce lightweight components from tubular blanks, there are only a few scientific works that have addressed material characteristics like the work hardening or residual stress that are linked to the process and machine parameters and the resulting material flow. Due to micro scale specifics that follow from the kinematics, i.e. relatively smaller stiffness against part buckling and wider tool gaps in the opened state, the feed rates achievable cannot compete with high throughput technologies that produce 500 parts per minute and more. One major aim of the project "Rotary swaging of micro parts" was to increase the productivity for the main process variants, namely infeed and plunge rotary swaging. This demanded also process modeling to understand how parameter variations like friction between tools and the work in the different zones of the swaging tools affect the process.From the modeling and simulation, separate process variations were deduced and investigated. For infeed swaging, a special workpiece clamping allows for compensation of the pushback force, which results in a 10-fold increase of the maximum feed rate. For plunge rotary swaging, an approach was tested to close the tools gaps during opening using elastic intermediate elements that encapsule the workpiece against the forming dies and enable a 4-fold increase of the radial feed rate. 28 B. Kuhfuss et al.Micro rotary swaging could become a base technology ...

show abstract

Tube/tube joining technology by using rotary swaging forming method

Cited by 52 publications

References 17 publications

Mechanical properties optimization of the steering column based on multi-objective optimization design

Mechanical properties optimization of the steering column based on multi-objective optimization design

Research on Integrated Casting and Forging Process of Aluminum Automobile Wheel

Micro Forming Processes

Contact Info

Product

Resources

About