Swaging process
description
Transcript of Swaging process
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Finite element analysis of a tube swaging process
1) Graduate student of Gyeongsang National University(GNU), Jinju / Korea; 2) TIC of Gyeongsang National University; 3) Korea Institute of Industrial Technology, Incheon / Korea; #) School of Mechanical and Areospace Engineering, GNU, Jinju / Korea, [email protected]
Korean Society for Technology of Plasticity
Mincheol Kim 1), Jaegun Eom 2) , Sungju Lim3), Hojun Choi3) , ManSoo Joun #
www.afdex.com
AFDEX
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Contents
⊙ Research background
⊙ Analysis model
⊙ Condition of finite element analysis
⊙ History of deformation
⊙ Animation
⊙ Conclusions
⊙ Future plans
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Research background
⊙ The advantage of swaging process
○ Various shapes as round, square, tapered shape of products, the swaging process is very
advantageous for mass production
○ Because equipments inexpensive and simple, easy to work with anyone that is unskilled
○ Because of chipless forming, material savings can be applied to large and non-ferrous materials
○ Available forming at cold and hot temperatures
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Research background
⊙ Literature search
○ Piela, Grosman and Piela: assume 2-dimentional problem
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Research background
⊙ Literature search
○ H.J.Jeong et. al., FEA
Prediction-DEFORMTM
Before After
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Research background
⊙ Objective of research
○ The rigid-plastic finite element method is used.
○ Simulate a tube swaging process
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Spindle head Control panel
4- Split die
Thicker shim plate
Equipment and dies of rotary swaging
Developed rotary swaging machine (RSM25)
Reference: Korea Institute of Industrial Technology
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Equipment and dies of rotary swaging
Developed rotary swaging die
Design of swaging die Manufacture of swaging die
Reference: Korea Institute of Industrial Technology
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Analysis model
Schematic diagram of a swaging process and Analysis model
Radial motion
of die
Radial motion
of die
Longitudinal motion
of workpiece
Longitudinal motion
of pusher
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⊙ Forming speed [mm/rev.]
○ Workpiece longitudinal speed: mm/s ○ Spindle number of revolution: rpm
⊙ Reduction of area
Parameters Parameters Value
Tube:STKM11A Solid:S45C 25
Reduction of Reduction of 40
50
60
Ratio of t/d t/d Δd(%) Forming 0.5
Reduction of 1/10 15 speed 1.0
diameter(%) 1/20 30 (mm/rev.) 1.5
1/30 50 2.0
area(%)55diameter(%)
Value
30
45
Feed speed
(mm/min)
Spindle
revolution(rpm)200 200 200 200
Forming speed
(mm/rev)
100 200 300 400
0.5 1 1.5 2
(mm/min)(mm/rev) =
(rev/min)
Workpiece longitudinal Forming speed
Spindle number of revolution
Variation of forming process
Reference: Korea Institute of Industrial Technology
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Distance [mm]
Lo
ad
[kN
]
0 5 10 15 20 25 300
5
10
15
20
25
30
⊙ Flow stress
⊙ Coefficient of Coulomb friction
⊙ Velocity
○ Velocity of radial motion of dies
○ Velocity of longitudinal motion of workpiece
○ Angular velocity of workpiece
⊙ Cycle time: 1.108s
⊙ Back pressing force exerted by the pusher
Conditions of finite element analysis
0.22712.8962 MPa
D
rv
M
lv
Mw
Time [s]
Ve
locity
[mm
/s]
an
gu
lar
ve
locity
[de
g/s
]
0 0.2 0.4 0.6 0.8 1-15
-10
-5
0
5
10
15
0
20
40
60
80D
rv
M
lv
Mw
Velocities of workpiece and dies with time
0.05
Back pressing force exerted by the pusher
with the movement of the back end of the
workpiece
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History of deformation
Initial Blow. 10
Blow. 19 Blow. 28
Blow. 37 Blow. 46
Blow. 54 Blow. 67
⊙ Effective strain
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LS-Dyna
Compare experiment with prediction
Wrinkle Thickness
Reference: Korea Institute of Industrial Technology
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Animation
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Conclusions
⊙ A scheme of analyzing a swaging process by finite element method was presented.
⊙ For example, a circle-circle tube swaging process was simulated.
⊙ A backpressing die approach was proposed to reflect the reverse motion of the
workpiece.
⊙ Load on the backpressing die was imposed by the virtual body force technique.