Experimental and Numerical Analysis of Local Lateral Compression Process of Metal Tubes between Cylindrical Shaped Dies
محورهای موضوعی : Metal Forming
Hamzeh Kazemi
1
(
M.Sc. Graduate, Mechanical Engineering Department, Razi University, Kermanshah, Iran
)
Heshmatollah Haghighat
2
(
Associate Professor, Mechanical Engineering Department, Razi University, Kermanshah, Iran
)
کلید واژه: Tube Lateral Compression, Compression Force, Deformation Zone,
چکیده مقاله :
Metal tubes are widely used in various forms in engineering structures. Local deformation of the tube is required due to design considerations or the tube's location in the machine or structure to facilitate its installation. This paper investigates the process of locally laterally compressing aluminum tubes using experimental and numerical simulation methods. The tube is positioned horizontally on the fixed lower die and is subjected to compressive load by the upper die, which is connected to the movable ram of the press machine, resulting in plastic deformation. Both upper and lower dies are semi-cylindrical with equal radii, and their axes are perpendicular to the tube's axis. For the experimental and numerical analysis, two types of aluminum 6061-T6 tubes with the same outer diameter but different inner diameters were chosen, and three similar samples were created for each type. The true stress behavior, based on the true strain of the aluminum material, was determined from a simple tensile test. Subsequently, the geometric dimensions of the deformed area of the tubes were measured for various press strokes. The geometric shape of the deformation zone and the experimental forming load data were compared with the simulation results obtained using ABAQUS software. A comparison between the results from the two experimental and simulation methods demonstrated good agreement.
Metal tubes are widely used in various forms in engineering structures. Local deformation of the tube is required due to design considerations or the tube's location in the machine or structure to facilitate its installation. This paper investigates the process of locally laterally compressing aluminum tubes using experimental and numerical simulation methods. The tube is positioned horizontally on the fixed lower die and is subjected to compressive load by the upper die, which is connected to the movable ram of the press machine, resulting in plastic deformation. Both upper and lower dies are semi-cylindrical with equal radii, and their axes are perpendicular to the tube's axis. For the experimental and numerical analysis, two types of aluminum 6061-T6 tubes with the same outer diameter but different inner diameters were chosen, and three similar samples were created for each type. The true stress behavior, based on the true strain of the aluminum material, was determined from a simple tensile test. Subsequently, the geometric dimensions of the deformed area of the tubes were measured for various press strokes. The geometric shape of the deformation zone and the experimental forming load data were compared with the simulation results obtained using ABAQUS software. A comparison between the results from the two experimental and simulation methods demonstrated good agreement.
[1] Kobayashi, H. and Daimaruya, M. 1994. Dynamic and quasi-static lateral compression tests of ceramics tubes. Journal de Physique IV-Proceedings. 04:275-280. doi:10.1051/jp4:1994841.
[2] Avalle, M. and Gogllo, L. 1999. Lateral compression of thin-walled tubes strain measurement by image analysis. Experimental Mechanics. 3:231-235. doi: 10. 1007/BF02323557.
[3] Gupta, N.K., Sekhon, G.S. and Gupta, P.K. 2005. Study of lateral compression of round metallic tubes. Thin-Walled Structures. 43:895–922. doi:10.1016/j.tws.2004.12.002.
[4] Niknejad, A., Ali Elahi, S. and Liaghat, Gh. H. 2011. Experimental investigation on the lateral compression in the foam-filled circular tubes. Materials and Design. 36:24-34. doi:10.1016/j.matdes.2011.10.047.
[5] Rathnaweera, G., Durandet, Y., Ruan D. and Kinoshita, S. 2011. Characterizing the material properties of a tube from a lateral compression test. International Journal of Protective Structures. 2:465-475. doi:10.1260/2041-4196.2.4.465.
[6] Schiemann, T., Liewald, M., Beiermeister, C. and Till, M. 2014. Influence of process chain on fold formation during flange upsetting of tubular cold forged parts. Procedia Engineering. 81:352 – 357. doi:10.1016/j.proeng.2014.10.005.
[7] Nomura, T., Nguyen, C.S., Asai, K. and Kitamura, K. 2016. Behavior of asymmetric deformation of rod in locally-lateral upsetting Mechanical Engineering Journal. 3:1-7. doi:10.1299/mej.15-00576.
[8] Parvizi Bina E. and Haghighat H. 2021. Limit analysis of plane strain compression of cylindrical billets between flat dies. Journal of Advanced Manufacturing Technology. 116:1-10. doi:10.1007/s00170-021-07711-1.
[9] Pepelnjak, T., Šašek, P. and Kudlaček J. 2016. Upsetting Analysis of High-Strength Tubular Specimens with the Taguchi Method. Metals. 6:257. doi:10.3390/met6110257.
[10] Guan, Y., Li, C, Guo, S. and Lin, P. 2022. A novel combined process of flaring-upsetting for forming end flanges on thin-walled tubes. Journal of Manufacturing Processes. 84:927-936. doi:10.1016/j.jmapro.2022.10.051.
[11] Zhang, Z. 2022. Theoretical prediction of cross-sectional deformation of circular thin-walled tube in large elastic–plastic deformation stage under
