An approach for the forming of large-thickness-flange components by injection forging

Research output: Contribution to journalArticle

3 Citations (Scopus)

Abstract

Injection forging has advantages for the nett-forming of flange-typed components. Research, however, has identified that folds occurred on material free-surfaces during the injection upsetting of flanges when the billet-diameter/flange-thickness ratio was beyond 1.2. These occurred at lower aspect ratios than that defined with reference to the stability of the billets. FE simulation and experiments were conducted to identify approaches by which the initiation of folds could be prevented and, hence, the process range of injection forging could be improved. It was recognised that, since the folds develop for conditions under which the billets are stable (no buckling or lateral sliding), it is possible to design a forming route of more than one stage to prevent the development of the flaws and, hence, to extend formability. Through the research, a preforming procedure was developed by means of which the process range of injection forging of solid components can be extended to flange-thickness/billet-diameter ratios of 1.4–1.5 using machined preforms, and to 1.50–1.64 using preformed billets. The proposed preform enabled the forming of several flange-typed components without folds.
Original languageEnglish
Pages (from-to)153-162
Number of pages10
JournalJournal of Materials Processing Technology
Volume145
Issue number2
DOIs
Publication statusPublished - 15 Jan 2004

Fingerprint

Forging
Flanges
Injection
Fold
Formability
Preforming
Buckling
Aspect Ratio
Free Surface
Range of data
Lateral
Aspect ratio
Defects
Experiment
Simulation
Experiments

Keywords

  • forging
  • injection forging
  • forming defects
  • preform design

Cite this

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title = "An approach for the forming of large-thickness-flange components by injection forging",
abstract = "Injection forging has advantages for the nett-forming of flange-typed components. Research, however, has identified that folds occurred on material free-surfaces during the injection upsetting of flanges when the billet-diameter/flange-thickness ratio was beyond 1.2. These occurred at lower aspect ratios than that defined with reference to the stability of the billets. FE simulation and experiments were conducted to identify approaches by which the initiation of folds could be prevented and, hence, the process range of injection forging could be improved. It was recognised that, since the folds develop for conditions under which the billets are stable (no buckling or lateral sliding), it is possible to design a forming route of more than one stage to prevent the development of the flaws and, hence, to extend formability. Through the research, a preforming procedure was developed by means of which the process range of injection forging of solid components can be extended to flange-thickness/billet-diameter ratios of 1.4–1.5 using machined preforms, and to 1.50–1.64 using preformed billets. The proposed preform enabled the forming of several flange-typed components without folds.",
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author = "Y Qin and R Balendra",
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An approach for the forming of large-thickness-flange components by injection forging. / Qin, Y; Balendra, R.

In: Journal of Materials Processing Technology, Vol. 145, No. 2, 15.01.2004, p. 153-162.

Research output: Contribution to journalArticle

TY - JOUR

T1 - An approach for the forming of large-thickness-flange components by injection forging

AU - Qin, Y

AU - Balendra, R

PY - 2004/1/15

Y1 - 2004/1/15

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AB - Injection forging has advantages for the nett-forming of flange-typed components. Research, however, has identified that folds occurred on material free-surfaces during the injection upsetting of flanges when the billet-diameter/flange-thickness ratio was beyond 1.2. These occurred at lower aspect ratios than that defined with reference to the stability of the billets. FE simulation and experiments were conducted to identify approaches by which the initiation of folds could be prevented and, hence, the process range of injection forging could be improved. It was recognised that, since the folds develop for conditions under which the billets are stable (no buckling or lateral sliding), it is possible to design a forming route of more than one stage to prevent the development of the flaws and, hence, to extend formability. Through the research, a preforming procedure was developed by means of which the process range of injection forging of solid components can be extended to flange-thickness/billet-diameter ratios of 1.4–1.5 using machined preforms, and to 1.50–1.64 using preformed billets. The proposed preform enabled the forming of several flange-typed components without folds.

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KW - forming defects

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