Numerical and Experimental Study of Producing Two-Step Flanges by Extrusion with a Movable Sleeve

Open access

Abstract

The paper presents a new metal forming process for producing two-step external flanges on hollow parts. With this method, the flange is extruded by a movable sleeve, which moves in the opposite direction to the punch. This reduces the phenomenon of buckling of the tube wall, which allows extruding flanges with relatively large volumes. The new method was applied to produce a two-step flange on the end of a tubular billet made of 6060 aluminum alloy. This cold metal forming process was designed based on numerical simulations and experimental tests. The effect of the basic technological parameters on metal flow was investigated and limitations of the process were identified. The experimental results confirmed the possibility of forming a two-step flange with a diameter that is approximately twice as big as the external diameter of the tubular billet.

[1] O. Music, J.M. Allwood, K. Kawai, J. Mater. Process. Tech. 210 (1), 3-23 (2010).

[2] M.J. Davidson, K. Balasubramanian, G.R.N. Tagore, J. Mater. Process Tech. 203, 321-325 (2008).

[3] P. Skubisz, Ł. Lisiecki, J. Sińczak, Metalurgija 54 (2), 339-342 (2015).

[4] M. Wolfgarten, D. Rosenstock, L. Schaeffer, G. Hirt, Metall. Ital. 4, 43-49 (2015).

[5] S.J. Lim, H.J. Choi, C.H. Lee, J. Mater. Process Tech. 209 (1), 283-288 (2009).

[6] R. Hebdzyński, S. Kajzer, R. Kozik, J. Mater. Process Tech. 64, 199-206 (1997).

[7] G.C. Wang, G.Q. Zhao, X.H. Huang, Y.X Jia, J. Mater. Process Tech. 121, 259-264 (2002).

[8] Z. Pater, J. Tomczak, T. Bulzak, Metalurgija 54 (2), 419-422 (2015).

[9] J. Tomczak, Z. Pater, T. Bulzak, Int. J. Adv. Manuf. Tech. 82, 1281-1291 (2016).

[10] G. Winiarski, A. Gontarz, Z. Pater, Arch. Civ. Mech. Eng. 15 (4), 911-916 (2015).

[11] X.M. Qiu, L.H. He, J. Gu, X.H. Yu, Thin Wall. Struct. 80, 32-37 (2014).

[12] X.L. Hu, Z.R. Wang, J. Mater. Process Tech. 151, 321-327 (2004).

[13] A. Dziubińska, A. Gontarz, Metalurgija 54 (3) 555-558 (2015).

Archives of Metallurgy and Materials

The Journal of Institute of Metallurgy and Materials Science and Commitee on Metallurgy of Polish Academy of Sciences

Journal Information


IMPACT FACTOR 2016: 0.571
5-year IMPACT FACTOR: 0.776

CiteScore 2016: 0.85

SCImago Journal Rank (SJR) 2016: 0.347
Source Normalized Impact per Paper (SNIP) 2016: 0.740

Metrics

All Time Past Year Past 30 Days
Abstract Views 0 0 0
Full Text Views 190 190 13
PDF Downloads 70 70 4