An experimental and analytical investigation of flange forming by spinning process

Elmasry, Mohamed S.; Elmetwally, Hammad T.; El-Sheikh, Mohamed N.; Abdel-Magied, Ragab K.

doi:10.22061/jcarme.2019.5021.1612

فهرست نشریات

دانشگاه تربیت دبیر شهید رجائی

انتشارات دانشگاه تربیت دبیر شهید رجائی

نشریات مستقل دانشگاه در سامانه ارزیابی نشریات علمی وزارت علوم

نشریه معماری وشهرسازی پایدار موفق به اخذ رتبه علمی-پژوهشی شد

تعداد نشریات	11
تعداد شماره‌ها	222
تعداد مقالات	2,215
تعداد مشاهده مقاله	3,263,495
تعداد دریافت فایل اصل مقاله	2,346,316

	An experimental and analytical investigation of flange forming by spinning process
Journal of Computational & Applied Research in Mechanical Engineering (JCARME)
مقاله 4، دوره 11، شماره 1، آذر 2021، صفحه 35-46 اصل مقاله (824.37 K)
نوع مقاله: Research Paper
شناسه دیجیتال (DOI): 10.22061/jcarme.2019.5021.1612
نویسندگان
Mohamed S. Elmasry^* ¹؛ Hammad T. Elmetwally²؛ Mohamed N. El-Sheikh²؛ Ragab K. Abdel-Magied¹
¹Mechanical Engineering Department, Faculty of Engineering, Beni-Suef University, Beni-Suef, Egypt
²Production Technology Department, Faculty of Industrial Education, Beni-Suef University, Beni-Suef, Egypt
تاریخ دریافت: 05 فروردین 1398، تاریخ بازنگری: 18 آبان 1398، تاریخ پذیرش: 02 آذر 1398
چکیده
The tube flange is typically performed using welding, forging methods, which cost effort and time. In the present work, a metal spinning process to form tube flange was proposed. A flange-forming tool was developed based on the outer tube diameter to form the flange. It consists of three components namely; collet, mandrill, and roller. An experimental work was conducted to investigate the process parameters of the flange process of lead tubes. Different working conditions are considered during conducting of flanged specimens, e.g. rotating speed, feed rate, and tube wall thickness. The effects of the working conditions on the flanging loads were investigated. The results reveal that the flanging load increases with the increasing rotational speed, tube wall thickness, and with both lower and higher values of feed rate while it decreases with medium values of feed rates. To show the effect of the working conditions on the flange characteristics, a parametric study was conducted. The results show that the surface hardness and surface roughness of the formed flange is improved with increasing all working conditions. A theoretical analysis to model the flange forming loads (axial, radial and tangential) was presented. A comparison between forming loads analytically and experimentally was discussed. The comparison indicates that this percentage of error up to 4% occurs, instead of error percentage up to 28%, in case of neglecting the low feed rate.
کلیدواژه‌ها
Flange process؛ Metal tubes؛ Flanging ratio؛ Forming load

مراجع
[1] X. L. Hu and Z. R. Wang, “Numerical simulation and experimental study on the multi-step upsetting of a thick and wide ﬂange on the end of a pipe”, J. Mater. Process. Technol., Vol. 151, No. 1-3, pp. 321-327, (2004). [2] L. A. Isaevich, M. I. Sidorenko and V. A. Gurinovich, “Calculating the Deforming Force in Shaping the Flange of a Tubular Workpiece”, Russ. Eng. Res., Vol. 27, No. 5, pp. 275-278, (2008). [3] L. B. Aksenov and S. N. Kunkin, "Metal Flow Control at Processes of Cold Axial Rotary Forging" 2nd ed., Springer, New York, pp. 62–75, (2016). [4] Z. Wang, J. Lu and Z. R. Wang, “Numerical and experimental research of the cold upsetting-extruding of tube flanges”, J. Mater. Process. Technol., Vol. 110, No. 1, pp. 28-35, (2001). [5] T. Cao, B. Lu, H. Ou, H. Long and J. Chen “Investigation on a new hole-ﬂanging approach by incremental sheet forming through a featured tool” Int. J. Mach. Tools Manuf., Vol. 110, pp. 1-7, (2016). [6] Q. Lin, W. Dong, Z. Wang and K. Hirasawa, “A new hole-flanging method for thick plate by upsetting process,” Trans. Nonferrous Met. Soc. China, Vol. 24, No. 7, pp. 2387−2392, (2014). [7] V. Cristino, L. Montanari, M. B. Silva, A. G. Atkins and P. A. F. Martins, “Fracture in hole-ﬂanging produced by single point incremental forming”, Int. J. Mech. Sci., Vol. 83, pp. 46-154, (2014). [8] M. Borrego, D. Morales-Palma, A. J. Martinez-Donaire, G. Centeno and C. Vallellano, “On the study of the single-stage hole-flanging process by SPIF” Procardia Eng., Vol. 132 pp. 290 – 297, (2015). [9] T. Kumagai and Hiroyuki Saiki, “Deformation Analysis of Hole Flanging with Ironing of Thick Sheet Metals”, Met. Mater., Vol. 4, No. 4, pp. 711-714. (1998). [10] E. Haghani, A. Gheysarian and M. Honarpisheh “Design and manufacture a novel tool in the incremental sheet metal forming process and its effects on the process parameters”, J. Comput. Appl. Res. Mech. Eng., Vol. 8, No. 2, pp.121-132, (2018). [11] A. Gheysarian and M. Honarpisheh, “An experimental study on the process parameters of incremental forming of Al-Cu bimetal”, J. Comput. Appl. Res. Mech. Eng., Vol. 7. No. 1, pp. 73-83, (2017). [12] M. Borrego, D. Morales-Palma, A. J. Martinez-Donaire, G. Centeno and C. Vallellano “On the study of the single-stage hole-flanging process by SPIF” Procedia Eng., Vol. 132. No. 1, pp. 290–297, (2015). [13] S. Thipprakmas and W. Phanitwong, “Finite element analysis of flange-forming direction in the whole flanging process”, Into. J. Adv. Manu. Technol., Vol. 61, No. 5, pp. 609–620, (2012). [14] G. Hussain, H. Valaei, Khalid A. Al-Ghamdi and B. Khan “Finite element and experimental analyses of cylindrical hole flanging in incremental forming”, J. Mater. Process. Technol., Vol. 26, No. 9, pp. 2419−2425, (2016). [15] Y. M. Huang and K. H. Chien, “Inﬂuence of Cone Semi-Angle on the Formability Limitation of the Hole-Flanging Process”, Int. J. Adv. Manu. Technol. Vol. 19, No. 8, pp. 597–606, (2002). [16] A. Kacem, A. Krichen, P. Y. Manach, S. Thuillier and J. W. Yoon, “Failure prediction in the hole-ﬂanging process of aluminum alloys,” Eng. Fract. Mech., Vol. 99, pp. 251–265, (2013). [17] H. Soussi, N. Masmoudi and A Krichen, “Analysis of geometrical parameters and occurrence of defects in the hole-flanging process on thin sheet metal”, J. Mater. Process. Technol., Vol. 3, No. 2, pp. 22-34, (2015). [18] A. Kacem, A. Krichen and P. Manach, “Occurrence and effect of ironing in the hole-ﬂanging process,” J. Mater. Process. Technol., Vol. 211, No. 10, pp .1606–1613, (2011). [19] Gh. Payganeh, J. Shahbazi Karami and K. Malekzadeh Fard, "Finite element comparison of single, bi-layered and three-layered tube hydroforming processes”, J. Comput. Appl. Res. Mech. Eng., Vol. 2. No. 2, pp. 96-80, (2013). [20] O. Music, J. M. Allwood and K. Kawai, “A review of the mechanics of metal spinning”, J. Mater. Process. Technol., Vol. 210, No. 1, pp. 3‐23, (2009). [21] E. Hagan and J. Jeswiet, “A review of conventional and modern single‐point sheet metal forming methods, Procedings of the Institution of Mechanical Engineers, Part B”, J. Eng. Manuf., Vol. 217, No. 2, pp. 213‐225, (2003). [22] J. Jeswiet, F. Micari, G. Hirt and A. Bramley, “Asymmetric single point incremental forming of sheet metal”, CIRP Annals – Manuf. Technol., Vol. 54, No. 2, pp. 623‐649, (2005). [23] Q. X. Xia, “Investigation on the mechanism of the spinning technology of the 3D Non‐axisymmetric parts”, Chin. J. Mech. Eng., Vol. 40, No. 2, pp. 153‐156, (2004). [24] B. Awiszus and F. Meyer, “Metal spinning of non‐circular hollow parts”, Proce. Eighth Int. Conf. Technol. Plast., Vol. 3, pp. 353‐355, (2005). [25] B. Awiszus and S. Hartel, “Numerical simulation of non‐circular spinning: a rotationally non‐symmetric spinning process”, Prod. Eng. Res. Delve., Vol. 5, No. 6, pp. 605‐612, (2011). [26] D. Schmoeckel and S. Hauk, “Tooling and process control for splitting of disk blank”, J. Mater. Process. Technol., Vol. 98, No. 1, pp. 65-69, (2000). [27] Q. X. Xia, M. H. Yang, Y. Hu and X. Q. Cheng, “Numerical simulation and experimentation cup‐shaped thin‐walled inner rectangular gear formed by spinning”, Chin. J. Mech. Eng., Vol. 42, No. 12, pp. 192‐196, (2006). [28] C. C. Wong, T. A. Dean and J. Lin “A review of spinning, shear forming and ﬂow forming processes” Int. J. Mach. Tools Manuf., Vol. 43, No. 14, pp. 1419–1435, (2003). [29] G. Gwak, J. Jeon, J. Cho, J. Choi and J. Kim, “Development of Integrated Stub End by Spinning Process”, Int. J. Precis. Eng. Manuf., Vol. 16, No. 7, pp. 1473-1477, (2015). [30] S. Hess. B. Lossen, D. Biermann, W. Homberg and T. Wagner, “Analysis of the surface roughness obtained in a friction spinning process based on empirical models”, Int. J. Adv. Manuf. Technol., Vol. 74, No. 9, pp. 1655–1665, (2014). [31] O. I. Ahmed, M. N. El- Sheikh and A. A. Ibrahim, “An Investigation into Flanging of Tube Ends using Truncated Conical Plugs,” Bull. Fac. Eng., Vol. 17, No. 2, pp. 47-52, (1989). [32] M. N. El-Sheikh, A. T. Mohamed and A. A. Ibrahim, “Widening of aluminum tube using conical plugs”, Minia J. Eng. Technol., Vol. 9 No. 1, pp. 27-38, (1990). [33] M. N El-Sheikh, “An Investigation Into Flange Forming Of Metallic Tubes”, Proceeding of 6th ed., International conference (MDP6), Current Advances in Mechanical Design & Production, Cairo University, Egypt, (1996). [34] F. A. Mphamed, S. Zein El-Abden and M. Abdel-Rahman, “A rotary ﬂange forming process on the lathe using a ball-shaped tool”, J. Mater. Process. Technol., Vol. 170, No. 3, pp. 501–508, (2005).
آمار تعداد مشاهده مقاله: 1,485 تعداد دریافت فایل اصل مقاله: 705

سامانه مدیریت نشریات علمی. طراحی و پیاده سازی از سیناوب

پیوندهای مفید

پیوندهای مفید

اخبار و اعلانات

آمار

An experimental and analytical investigation of flange forming by spinning process