The Experts below are selected from a list of 90 Experts worldwide ranked by ideXlab platform
T A Dea - One of the best experts on this subject based on the ideXlab platform.
-
effects of roller path and geometry on the Flow Forming of solid cylindrical components
Journal of Materials Processing Technology, 2005Co-Authors: C C Wong, T A DeaAbstract:Abstract Flow Forming is used mainly to produce thin walled high precision tubular components. Due to the flexibility and low tool load requirement, the process is capable of being extended to the manufacture of shapes from bulk raw material, such as solid bar ingot, cast and forged preforms. In the work reported in this paper, a simple Flow Forming facility was established to enable the effects of roller path and geometry, on the Flow of metal, to be examined. An FE model has been developed to simulate the process, based on experimental conditions. The results show that, for a cylindrical roller moving axially along a work-piece, metal moves predominantly in a radial direction, Forming a flange. When a roller with a rounded contact region, ‘nosed’, is used, the metal Flow is predominantly axial. Radial roller movement results in the formation of a ‘cup’ or a ‘boss’ on the end of the work-piece. The dimensions of the feature depend on the roller geometry, feed rate and amount of deformation. The results illustrate the ability of Flow Forming to be used for production of shapes of thin section, which would be difficult and expensive to be made by press Forming.
-
incremental Forming of solid cylindrical components using Flow Forming principles
Journal of Materials Processing Technology, 2004Co-Authors: C C Wong, T A DeaAbstract:Abstract The Flow Forming process has been used to produce a range of engineering components, with reduced Forming loads and enhanced mechanical and surface quality for a finished part, compared with press formed parts. However, studies on the Flow Forming of solid cylindrical components have not been documented. In this paper, test facilities were established in order to study the effects of roller geometry and feed rate on Forming load and material Flow when Flow Forming a simple solid cylindrical component with uniform diameter, using lead as the material. Experiments are carried out to study the effects of feed rates and roller geometry on material Flow. A finite element (FE) model is proposed to simulate the process using ABAQUS implicit and explicit. The difficulties in simulating Flow Forming are outlined and the model using different formulations are compared for their efficiency in analysing the process.
-
a review of spinning shear Forming and Flow Forming processes
International Journal of Machine Tools & Manufacture, 2003Co-Authors: C C Wong, T A DeaAbstract:Abstract In the last two decades or so, spinning and Flow Forming have gradually matured as metal Forming processes for the production of engineering components in small to medium batch quantities. Combined spinning and Flow Forming techniques are being utilised increasingly due to the great flexibility provided for producing complicated parts nearer to net shape, enabling customers to optimise designs and reduce weight and cost, all of which are vital, especially in automotive industries. In this paper, process details of spinning and Flow Forming are introduced. The state of the art is described and developments in terms of research and industrial applications are reviewed. Also, the direction of research and development for future industrial applications are indicated.
C C Wong - One of the best experts on this subject based on the ideXlab platform.
-
effects of roller path and geometry on the Flow Forming of solid cylindrical components
Journal of Materials Processing Technology, 2005Co-Authors: C C Wong, T A DeaAbstract:Abstract Flow Forming is used mainly to produce thin walled high precision tubular components. Due to the flexibility and low tool load requirement, the process is capable of being extended to the manufacture of shapes from bulk raw material, such as solid bar ingot, cast and forged preforms. In the work reported in this paper, a simple Flow Forming facility was established to enable the effects of roller path and geometry, on the Flow of metal, to be examined. An FE model has been developed to simulate the process, based on experimental conditions. The results show that, for a cylindrical roller moving axially along a work-piece, metal moves predominantly in a radial direction, Forming a flange. When a roller with a rounded contact region, ‘nosed’, is used, the metal Flow is predominantly axial. Radial roller movement results in the formation of a ‘cup’ or a ‘boss’ on the end of the work-piece. The dimensions of the feature depend on the roller geometry, feed rate and amount of deformation. The results illustrate the ability of Flow Forming to be used for production of shapes of thin section, which would be difficult and expensive to be made by press Forming.
-
incremental Forming of solid cylindrical components using Flow Forming principles
Journal of Materials Processing Technology, 2004Co-Authors: C C Wong, T A DeaAbstract:Abstract The Flow Forming process has been used to produce a range of engineering components, with reduced Forming loads and enhanced mechanical and surface quality for a finished part, compared with press formed parts. However, studies on the Flow Forming of solid cylindrical components have not been documented. In this paper, test facilities were established in order to study the effects of roller geometry and feed rate on Forming load and material Flow when Flow Forming a simple solid cylindrical component with uniform diameter, using lead as the material. Experiments are carried out to study the effects of feed rates and roller geometry on material Flow. A finite element (FE) model is proposed to simulate the process using ABAQUS implicit and explicit. The difficulties in simulating Flow Forming are outlined and the model using different formulations are compared for their efficiency in analysing the process.
-
a review of spinning shear Forming and Flow Forming processes
International Journal of Machine Tools & Manufacture, 2003Co-Authors: C C Wong, T A DeaAbstract:Abstract In the last two decades or so, spinning and Flow Forming have gradually matured as metal Forming processes for the production of engineering components in small to medium batch quantities. Combined spinning and Flow Forming techniques are being utilised increasingly due to the great flexibility provided for producing complicated parts nearer to net shape, enabling customers to optimise designs and reduce weight and cost, all of which are vital, especially in automotive industries. In this paper, process details of spinning and Flow Forming are introduced. The state of the art is described and developments in terms of research and industrial applications are reviewed. Also, the direction of research and development for future industrial applications are indicated.
Jie Dong - One of the best experts on this subject based on the ideXlab platform.
-
grain refinement and orientation of az31b magnesium alloy in hot Flow Forming under different thickness reductions
Journal of Materials Science & Technology, 2017Co-Authors: Yalia Zhang, Fenghua Wang, Jie Dong, Conghui Liu, Wenjiang DingAbstract:Abstract An analysis of the hot Flow Forming of Mg-3.0Al-1.0Zn-0.3Mn (AZ31B) alloy was conducted by experiments and numerical simulations. The effects of different thickness reductions on the microstructure and mechanical properties were investigated at a temperature of 693 K, a spindle speed of 800 rev/min and a feed ratio of 0.1 mm/rev. Thickness reductions have great influence on the uniformity of microstructure along the radial direction (RD) and the grain sizes become refined and uniform when the thickness reduction reaches 45%. The c -axes of most grains are approximately parallel to the RD, with a slight inclination towards the axial direction (AD). The best mechanical properties with UTS of 280 MPa and YS of 175 MPa near the outer surface while 266 MPa and 153 MPa near the inner surface have been achieved due to grain refinement and texture. Moreover, the material Flow behavior and stress/strain distributions for single-pass reductions were studied using the ABAQUS/Explicit software. The calculated results indicate that the materials mainly suffer from triaxial compressive stresses and undergo compressive plastic strain in RD and tensile strains in other directions. The higher stress and strain rate near the outer surface lead to more refined grains than that of other regions along the RD, whereas the orientation of the maximum principal compressive stress leads to a discrepancy of the grain orientations in RD.
-
microstructure and mechanical properties of az80 magnesium alloy tube fabricated by hot Flow Forming
Materials & Design, 2015Co-Authors: Zhe Cao, Fenghua Wang, Zhenya Zhang, Jie DongAbstract:Abstract Flow Forming is a plastic deformation process to produce thin-walled and high-precision cylindrical components. In this study, the hot Flow Forming of Mg–8.5Al–0.5Zn–0.2Mn (AZ80) alloy tubes was conducted innovatively. The effects of processing parameters including Flow Forming temperature, spindle speed, feed ratio and thickness reduction on the microstructures and mechanical properties of AZ80 alloy tubes were investigated. The results show that a more unanimous and raised grain size appeared with deForming temperature from 300 to 420 °C. The variation of spindle speed and feed ratio had a slight influence on the microstructure, but an obvious influence on the tensile properties, particularly the elongation. With increasing the thickness reduction, the grain size decreased while the micro-hardness increased significantly. The electron backscatter diffraction (EBSD) results show that the c-axes of most grains are approximately parallel to the radial direction. And likewise, they have a slight deflection towards the axial direction. Furthermore, ultimate tensile strength (UTS) of 308 MPa and elongation of 9.8% were obtained when the hot Flow Forming was carried out under a temperature of 420 °C, a spindle speed of 400 rev/min, a feed ratio of 0.1 mm/rev and a thickness reduction of 45%.
Fenghua Wang - One of the best experts on this subject based on the ideXlab platform.
-
grain refinement and orientation of az31b magnesium alloy in hot Flow Forming under different thickness reductions
Journal of Materials Science & Technology, 2017Co-Authors: Yalia Zhang, Fenghua Wang, Jie Dong, Conghui Liu, Wenjiang DingAbstract:Abstract An analysis of the hot Flow Forming of Mg-3.0Al-1.0Zn-0.3Mn (AZ31B) alloy was conducted by experiments and numerical simulations. The effects of different thickness reductions on the microstructure and mechanical properties were investigated at a temperature of 693 K, a spindle speed of 800 rev/min and a feed ratio of 0.1 mm/rev. Thickness reductions have great influence on the uniformity of microstructure along the radial direction (RD) and the grain sizes become refined and uniform when the thickness reduction reaches 45%. The c -axes of most grains are approximately parallel to the RD, with a slight inclination towards the axial direction (AD). The best mechanical properties with UTS of 280 MPa and YS of 175 MPa near the outer surface while 266 MPa and 153 MPa near the inner surface have been achieved due to grain refinement and texture. Moreover, the material Flow behavior and stress/strain distributions for single-pass reductions were studied using the ABAQUS/Explicit software. The calculated results indicate that the materials mainly suffer from triaxial compressive stresses and undergo compressive plastic strain in RD and tensile strains in other directions. The higher stress and strain rate near the outer surface lead to more refined grains than that of other regions along the RD, whereas the orientation of the maximum principal compressive stress leads to a discrepancy of the grain orientations in RD.
-
microstructure and mechanical properties of az80 magnesium alloy tube fabricated by hot Flow Forming
Materials & Design, 2015Co-Authors: Zhe Cao, Fenghua Wang, Zhenya Zhang, Jie DongAbstract:Abstract Flow Forming is a plastic deformation process to produce thin-walled and high-precision cylindrical components. In this study, the hot Flow Forming of Mg–8.5Al–0.5Zn–0.2Mn (AZ80) alloy tubes was conducted innovatively. The effects of processing parameters including Flow Forming temperature, spindle speed, feed ratio and thickness reduction on the microstructures and mechanical properties of AZ80 alloy tubes were investigated. The results show that a more unanimous and raised grain size appeared with deForming temperature from 300 to 420 °C. The variation of spindle speed and feed ratio had a slight influence on the microstructure, but an obvious influence on the tensile properties, particularly the elongation. With increasing the thickness reduction, the grain size decreased while the micro-hardness increased significantly. The electron backscatter diffraction (EBSD) results show that the c-axes of most grains are approximately parallel to the radial direction. And likewise, they have a slight deflection towards the axial direction. Furthermore, ultimate tensile strength (UTS) of 308 MPa and elongation of 9.8% were obtained when the hot Flow Forming was carried out under a temperature of 420 °C, a spindle speed of 400 rev/min, a feed ratio of 0.1 mm/rev and a thickness reduction of 45%.
G R N Tagore - One of the best experts on this subject based on the ideXlab platform.
-
surface roughness prediction of Flow formed aa6061 alloy by design of experiments
Journal of Materials Processing Technology, 2008Co-Authors: Joseph M Davidson, K Balasubramanian, G R N TagoreAbstract:Abstract Design of experiments has been used to study the effects of the main Flow-Forming parameters such as the speed of the mandrel, the longitudinal feed, and the amount of coolant used on the surface roughness of Flow-formed AA6061 tube. A mathematical prediction model of the surface roughness has been developed in terms of the above parameters. The effect of these parameters on the surface roughness has been investigated using response surface methodology (RSM). Response surface contours were constructed for determining the optimum Forming conditions for a required surface roughness. The developed prediction equation shows that the longitudinal feed rate is the most important factor that influences the surface roughness. The surface roughness was found to increase with increase in the longitudinal feed and it decreased with decrease in the amount of the coolant used. The verification experiment carried out to check the validity of the developed model predicted surface roughness within 6% error.
-
experimental investigation on Flow Forming of aa6061 alloy a taguchi approach
Journal of Materials Processing Technology, 2008Co-Authors: Joseph M Davidso, K Alasubramania, G R N TagoreAbstract:Abstract An annealed AA6061 aluminum tubing preform was cold Flow-formed into a seamless tube. A multiple pass Flow-Forming was performed. In this investigation, the influence of the various Flow-Forming process parameters on the percentage elongation (%D) has been analyzed. The parameters considered are the speed of the mandrel, S (rpm), the depth of cut, Dc (mm) and the feed, F (mm/min). The effects of these input parameters on the response, percentage elongation (%D) have been critically analyzed using Taguchi method. It has been found that the depth of cut is the most important process parameter affecting the percentage elongation. The Flow-Forming process produced a maximum percentage elongation of 18% when the process parameters were set at their optimum values.