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Study On The Mechanism of Force Calculations in Flow Forming A Review/study On The Mechanism of Force Calculations in Flow Forming A Review
Study On The Mechanism of Force Calculations in Flow Forming A Review/study On The Mechanism of Force Calculations in Flow Forming A Review
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0976 6480(Print), ISSN 0976 6499(Online) Volume 4, Issue 3, April (2013), IAEME
ENGINEERING AND TECHNOLOGY (IJARET)
ISSN 0976 - 6480 (Print)
ISSN 0976 - 6499 (Online)
Volume 4, Issue 3, April 2013, pp. 194-201
IAEME: www.iaeme.com/ijaret.asp
Journal Impact Factor (2013): 5.8376 (Calculated by GISI)
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IJARET
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ABSTRACT
In metal working industry, flowforming processes is widely used. Flow forming is a metal
forming process in which a shorter and thinner ring, called preform, is elongated to a thin and long tube
over a rotating mandrel by means of three rollers. In this method, a hollow axisymmetric preform is
affixed to a mandrel. When the both are made to rotate, compression forces can be applied on the
outside diameter of the preform by hydraulically-driven CNC-controlled rollers. By a premeasured
quantity of wall thickness reduction, in one or more passes, the material is compressed above its yield
strength, plastically deformed and made to flow. The needed geometry of the workpiece is gained and
equipped when the outer diameter and the wall of the preform are reduced and the available material
volume is forced to flow longitudinally over the mandrel. Typically, the preform can be flowformed up
to six times its starting length before a need for reannealing of the metal is required. There are certain
parameters like mandrel speed, roller feed, roller geometry etc. which directly affect the dimensional
accuracy of flow formed component. In connection to these parameters the work piece metallurgical
properties like hardness variation and grain size variation will have effect on the dimensional accuracy
of flow formed components. The inside surface quality of the finished workpiece almost resembles
with the outside surface quality of the mandrel. Flow forming is used to produce rocket nose cones,
rocket motor cases, gas turbine components and dish antennas in the aerospace industry. It can also be
used to produce power train components and wheels in the automobile industry, gas bottles and
containers for storage applications. The analysis of flow forming has been undertaken by several
researchers. Most of the work is on the soft materials like lead, aluminum, low carbon steel, copper etc.
A very few authors have tried with the forming process of hard-to-work materials. Concise definitions
194
1. INTRODUCTION
Flow forming is a relatively new technique which is ideally suited to take the place of the current
forging and machining processes in components like the mortar tube. The flow forming operation
begins with a considerably short and thick-walled hollow cylinder preform.The preform is fit to a
mandrel with the same diameter as the product. Circumferential rollers rotate axially along the preform,
thus cold working the billet, making it thinner and longer, until it has a near net shape to that of the
finished mortar tube. Flow forming produces a highly uniform, round and smooth, surface finish. The
amount of time spent on machining is additionally reduced, which effectively reduces fluid
replacement costs after machining. For most applications three rollers are used.
2. CLASSIFICATION OF FLOW FORMING
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The classification of Flow forming process can be done based on two criteria.
(i) According to fixing necessities of preform shapes.
(ii) According to length of position of rolls during the forming process.
2.1. According to fixing necessities of preform shapes
The First type is forward flow forming (Fig.1) and it is used to form preforms which have a
shape with one side is partially closed or fully closed. In forward flow forming, a tailstock is used to fix
the preform to the mandrel. The elongation of the workpiece during forward flow forming is at the same
direction with the relative axial movement of the rollers. Second type of flow forming is backward flow
forming (Fig.2) and it is used to form preforms with a constant hole inside. In backward flow forming,
a toothed ring is used to fix the preform to the mandrel and it is also used for reloading of the finished
workpiece. The elongation of the workpiece during backward flow forming is at the opposite direction
to the relative axial movement of the rollers. For precision long flow forming operations, typically three
rollers placed with 120 design is used. These rollers have precalculated radial and axial offsets
between each other to achieve necessary forming conditions shown in (Figs.3,4). The analysis of tube
making has been adopted by several researchers.
2.2. According to the length of position of rolls during the forming process
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Fast and economical production rates inclined to other methods various applications are listed
Tubular- type components i.e., Missile casings, flight and launch motor housings, Rockets and
cartridge case.
Rocket nose cones, rocket motor cases, gas turbine components and dish antennas in the
aero-space Industry.
Power trained components and wheels in the Automobile Industry, and gas bottles and
containers for storage applications.
The manufacturing of thin walled tubes and closed and cylinders for the chemical, nuclear,
food, pharmaceutical, cryogenic, beverage, filtration and printing Industries.
Mass production of small containment vessels for drum packages.
Various typical applications are shown in fig.8. Furthermore, flow forming produces a highly uniform,
round and smooth, surface finish. Flow forming method also allows achieving high dimensional
accuracies and required to mechanical properties.
According to the analytical models stated above, most of the researchers have worked on the soft
materials like lead, aluminum, low carbon steel, copper etc. A very few authors have tried with the
forming process of hard-to-work materials. A brief description of the work done by other researchers on
soft as well as hard-to-work materials was studied. The studies revealed that more power was consumed
while working on the hard materials. While working on soft materials observed that the increase in
percentage of reduction, increase in power consumption of radial force and axial force. As the diameter
of the roller increases there was increase in power consumption, axial force and the radial force. This is
due to the fact that as the diameter of the roller increases, more volume of the material comes into
contact due to which more power and forces are required.
Most of the analytical models developed the tangential force by few authors. This is because
the tangential force consumes most of the power in the Spinning, and it is thus significantly important
for the design of spinning machines. From the calculations the tool force based on the assumption that
the deformation mode in spinning is a combination of bending and shearing. Moreover, by assuming
uniform roller contact pressure,
Through comparing the finite element simulation results with the Thamasett algorithm
calculation results of spinning forces, the finite element simulation results differ slightly from the
Thamasett algorithm calculation results of the spinning force measurement experimental results.
As review, a result of the flow formed component will have considerably higher mechanical properties
than the ones of the starting material. Typically, the preform material is plastically deformed with wall
reductions causing a substantial refinement of the grain structure and a total realignment of the grains
microstructure in Flow forming method also allows to achieve high dimensional accuracies and
required mechanical properties.
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