Finite element and experimental investigation of the direct flow forming process of thin-walled high-strength steel tubes

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Boroumand Panah Hamid; Naddaf Oskouei Alireza

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Journal Paper

Paper Information

Journal: Mechanics of Advanced and Smart Materials journal Year:2024 | Volume: | Issue: Page(s): 122-138

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Information Journal Paper

Title

Finite element and experimental investigation of the direct flow forming process of thin-walled high-strength steel tubes

Author(s)

Boroumand Panah Hamid | Naddaf Oskouei Alireza | Issue Writer Certificate

Keywords

Flow FormingQ4

High strength steelQ4

feed rateQ4

FEMQ4

Abstract

Tube Flow Forming is one of the most cost-effective production methods for creating simple cylindrical tubes with external and internal protrusions, with or without flanges. The dimensional accuracy of tubes produced by this method is higher than that of other methods, making it widely used in the aerospace industry. In this study, the Flow Forming process of three-roller high-strength steel was investigated through finite element analysis and compared with experimental results. The forming process was investigated for various mandrel rotation speeds and feed rates. By comparing the experimental results, the effects of each parameter on the surface quality (roughness), geometric quality and accuracy of the manufactured product (out-of-roundness, diametral increase) were studied. The results showed that the surface roughness of the final product increases with the increase in the feed rate. Increasing the feed rate also leads to a reduction in out-of-roundness and thus improves the geometric quality of the final product. Increasing the mandrel rotation speed results in a reduction in the surface roughness. Increasing the rotation speed also result in an increase in the out-of-roundness of the product.

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