Instability analysis in incremental rotary forming of tube flanges

Research output: Chapter in Book/Report/Conference proceedingConference contribution book

Abstract

Rotary forming is an exciting route for forming flanges of different angles from seamless tubes of high-strength materials. True to its incremental nature, the process offers great flexibility, but the issues encountered are atypical and complex. One such issue observed in experimental trials is the internal buckling of tubes during specific instances of flange formation. The origin of this instability is non-trivial, and ordinarily, finite-element (FE) models fail to capture this instability. To analyse and understand the problem, systematic experimental trials were carried out using different tube thicknesses, tube materials, and tool kinematics. This paper summarises the results from a critical analysis to establish (1) a criteria for quantifying the instability and identifying the instances of its occurrence, (2) a validation methodology to fine-tune FE models for the process, and (3) use of FE models to understand the influence of tool path in the flange forming stage.
Original languageEnglish
Title of host publicationForming the Future - Proceedings of the 13th International Conference on the Technology of Plasticity
Subtitle of host publicationProceedings of the 13th International Conference on the Technology of Plasticity
EditorsGlenn Daehn, Jian Cao, Brad Kinsey, Erman Tekkaya, Anupam Vivek, Yoshinori Yoshida
Place of PublicationCham, Switzerland
PublisherSpringer
Pages403-415
Number of pages13
ISBN (Electronic)9783030753818
ISBN (Print)9783030753801
DOIs
Publication statusPublished - 11 Jul 2021
EventThe 13th International Conference on the Technology of Plasticity: ICTP 2021 - Ohio State University, Ohio-Columbus, United States
Duration: 25 Jul 202130 Jul 2021

Publication series

NameMinerals, Metals and Materials Series
ISSN (Print)2367-1181
ISSN (Electronic)2367-1696

Conference

ConferenceThe 13th International Conference on the Technology of Plasticity
Country/TerritoryUnited States
CityOhio-Columbus
Period25/07/2130/07/21

Keywords

  • rotary forming
  • flange forming
  • incremental bulk forming
  • process instabilities
  • tool kinematics

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