Experimental Investigation of Effective Parameters on a New Incremental Tube Bulging Method Using Rotary Tool

محورهای موضوعی : Mechanical Engineering

S. M. H. Seyedkashi ¹ (Department of Mechanical Engineering, University of Birjand, Iran)
S. J. Hashemi Ghiri ² (Department of Mechanical Engineering, Kar Higher Education Institute, Iran)
F. Rahmani ³ (Department of Mechanical Engineering, University of Birjand, Iran)

تاریخ دریافت : 1395/10/30 تاریخ پذیرش : 1395/12/15 تاریخ انتشار : 1396/06/02

کلید واژه: Thinning, Forming Pitch, Dieless tube Forming, Feeding Depth,

چکیده مقاله :

Nowadays, dieless and flexible sheet forming methods are gaining much interest in prototyping and low production. In this research, a new method is developed to change the cross-sectional area of metal tubes in a longitudinal direction without using special dies. This technique is based on the force applied by a rotary tool to the inside/outside surface wall of a tube. The forming tool is mounted on a CNC milling machine and moves spirally with a specific pitch. In order to study the effects of process parameters on the product quality, a full factorial design of experiments was designed and performed. The input parameters were the feeding depth, forming pitch and tool velocity. Three responses including roughness, minimum thickness and production time were precisely measured for this purpose. The results showed that surface quality and minimum thickness is reduced with increasing the forming pitch and feeding depth. Tool rotational velocity does not have a significant effect on the forming parameters except for production time. Using a multi-objective response optimization, forming pitch of 0.25 mm, feeding depth of 1.25 mm and velocity of 800 mm/min were found to be the best configuration.

منابع و مأخذ:

[1]       Emmens, W., Van den Boogaard, A., “An Overview of Stabilizing Deformation Mechanisms in Incremental Sheet Forming”, Journal of Materials Processing Technology, Vol. 209, No. 8, 2009, pp. 3688-3695.

[2]        Ji, Y., Park, J., “Formability of Magnesium AZ31 Sheet in the Incremental Forming at Warm Temperature”, Journal of Materials Processing Technology, Vol. 201, No. 1, 2008, pp. 354-358.

[3]        Li, Y., Daniel, W. J., Liu Z., Lu H., and Meehan, P. A., “Deformation Mechanics and Efficient Force Prediction in Single Point Incremental Forming”, Journal of Materials Processing Technology, Vol. 221, No. 0, 2015, pp. 100-111.

[4]       Ambrogio, G., Gagliardi, F., Bruschi, S., and Filice, L., “On the High-Speed Single Point Incremental Forming of Titanium Alloys”, CIRP Annals - Manufacturing Technology, Vol. 62, No. 1, 2013, pp. 243-246.

[5]       Hamilton, K., Jeswiet, J., “Single Point Incremental Forming at High Feed Rates and Rotational Speeds: Surface and Structural Consequences”, CIRP Annals - Manufacturing Technology, Vol. 59, No. 1, 2010, pp. 311-314.

[6]       Wen, T., Zhang, S., Zheng, J., Huang, Q., and Liu, Q., “Bi-directional Dieless Incremental Flanging of Sheet Metals Using a Bar Tool with Tapered Shoulders”, Journal of Materials Processing Technology, Vol. 229, 2016, pp. 795-803.

[7]       Korkolis, Y. P., and Kyriakides, S., “Inflation and Burst of Anisotropic Aluminum Tubes for Hydroforming Applications”, International Journal of Plasticity, Vol. 24, No. 3, 2008, pp. 509-543.

[8]       Chu, E., Xu, Y., “Hydroforming of Aluminum Extrusion Tubes for Automotive Applications. Part I: Buckling, Wrinkling and Bursting Analyses of Aluminum Tubes”, International Journal of Mechanical Sciences, Vol. 46, No. 2, 2004, pp. 263-283.

[9]       Chu, E., Xu, Y., “Hydroforming of Aluminum Extrusion Tubes for Automotive Applications. Part II: Process Window Diagram”, International Journal of Mechanical Sciences, Vol. 46, No. 2, 2004, pp. 285-297.

[10] Seyedkashi, S., Moslemi Naeini, H., Liaghat, G. H., Mashadi Mosavi, M., Mirzaali, M., Shojaee, K., and Moon, Y. H., “The Effect of Tube Dimensions on Optimized Pressure and Force Loading Paths in Tube Hydroforming Process”, Journal of mechanical science and technology, Vol. 26, No. 6, 2012, pp. 1817-1822.

[11]  Hashemi, S. J, Moslemi Naeini, H., Liaghat, G. H., Azizi Tafti, R., and Rahmani, F., “Numerical and Experimental Investigation of Temperature Effect on Thickness Distribution in Warm Hydroforming of Aluminum Tubes”, Journal of Materials Engineering and Performance, Vol. 22, No. 1, 2013, pp. 57-63.

[12]  Seyedkashi, S. M. H., Moslemi Naeini, H., and Moon, Y. H., “Feasibility Study on Optimized Process Conditions in Warm Tube Hydroforming”, Journal of Mechanical Science and Technology, Vol. 28, No. 7, 2014, pp. 2845-2852.

[13]  Yang, C., Wen, T., Liu, L. T., Zhang, S., and Wang, H., “Dieless Incremental Hole-Flanging of Thin-Walled Tube for Producing Branched Tubing”, Journal of Materials Processing Technology, Vol. 214, No. 11, 2014, pp. 2461-2467.

[14]  Teramae, T., Manabe, K., Ueno K., Nakamura, K., and Takeda, H., “Effect of Material Properties on Deformation Behavior in Incremental Tube-Burring Process Using a Bar Tool”, Journal of Materials Processing Technology, Vol. 191, No. 1, 2007, pp. 24-29.

[15] Wen, T., Yang, C., Zhang, S., and Liu, L., “Characterization of Deformation Behavior of Thin-Walled Tubes During Incremental Forming: A Study with Selected Examples”, The International Journal of Advanced Manufacturing Technology, Vol. 78, No. 9, 2015, pp. 1769-1780.

[16] Cao, T., Lu, B., Ou, H., Long, H., and Chen, J., “Investigation on a New Hole-Flanging Approach by Incremental Sheet Forming Through a Featured Tool”, International Journal of Machine Tools and Manufacture, Vol. 110, No. 30, pp. 1-17.

[17]  Hussain, G., Valaei, H., Al-Ghamdi, K. A., and Khan, B., “Finite Element and Experimental Analyses of Cylindrical Hole Flanging in Incremental Forming”, Transactions of Nonferrous Metals Society of China, Vol. 26, No. 9, pp. 2419-2425.