swaging process
DESCRIPTION
Swanging processTRANSCRIPT
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
Contents
⊙ Research background
⊙ Analysis model
⊙ Condition of finite element analysis
⊙ History of deformation
⊙ Animation
⊙ Conclusions
⊙ Future plans
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
Research background
⊙ Literature search
○ Piela, Grosman and Piela: assume 2-dimentional problem
Research background
⊙ Literature search
○ H.J.Jeong et. al., FEA
Prediction-DEFORMTM
Before After
Research background
⊙ Objective of research
○ The rigid-plastic finite element method is used.
○ Simulate a tube swaging process
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
Equipment and dies of rotary swaging
Developed rotary swaging die
Design of swaging die Manufacture of swaging die
Reference: Korea Institute of Industrial Technology
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
⊙ 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
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
History of deformation
Initial Blow. 10
Blow. 19 Blow. 28
Blow. 37 Blow. 46
Blow. 54 Blow. 67
⊙ Effective strain
LS-Dyna
Compare experiment with prediction
Wrinkle Thickness
Reference: Korea Institute of Industrial Technology
Animation
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.