Flow-induced folding in multi-scaled bulk forming of axisymmetric flanged parts and its prediction and avoidance

The quality of manufactured parts and the efficiency of forming processes are crucial in deformation-based manufacturing. In product miniaturization and micro-manufacturing, size effect induces many unknowns. Flow-induced folding related to size effect is one of them and has not yet been fully studi...

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Bibliographic Details
Published in:International journal of advanced manufacturing technology 2022-04, Vol.119 (9-10), p.5863-5883
Main Authors: Zheng, Jun-Yuan, Fang, Jie Yi Chen, Fu, Ming Wang
Format: Article
Language:English
Subjects:
Advanced manufacturing technologies
Avoidance
CAE) and Design
Computer-Aided Engineering (CAD
Cracks
Defects
Deformation
Deformation effects
Design
Design analysis
Design defects
Energy consumption
Engineering
Extrusion
Folding
Industrial and Production Engineering
Manufacturing
Mechanical Engineering
Media Management
Metal forming
Miniaturization
Original Article
Size effects
Stress concentration
Tooling
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Summary:The quality of manufactured parts and the efficiency of forming processes are crucial in deformation-based manufacturing. In product miniaturization and micro-manufacturing, size effect induces many unknowns. Flow-induced folding related to size effect is one of them and has not yet been fully studied. In this research, the formation mechanism of folding defects in axisymmetric bulk forming was investigated, and a design-based method was employed to evaluate different tooling and process route designs for making a case-study multi-flanged part with three features and to explore the design-based avoidance of folding defects. In addition, a design evaluating framework of folding-free bulk forming was proposed, implemented, and validated. Via analysis of the material flow, energy consumption, folding formation, and product precision of the four proposed forming processes for the case-study part, an upsetting-extrusion forming method via using a nested punch was found to be the most desirable. It was then implemented in the physical forming with three size scales. The results revealed that the flow-induced folding in the macropart was severe and regularly circuitous, but it is slight and irregular in meso- and micro-scale. These findings are useful in the defect-free forming of multi-flanged structures and multi-scaled axisymmetric parts.
ISSN:0268-3768
1433-3015
DOI:10.1007/s00170-021-08382-8