Experimental investigation on tube flaring with a rotating tool

E. M. Mamros, Chetan P. Nikhare

Research output: Contribution to journalConference article

Abstract

As the automotive industry becomes increasingly competitive, manufacturers are striving to design the lightest, most fuel-efficient vehicles to capture the market. To achieve this mission, the material processing techniques used in vehicle manufacturing must be investigated further. One such critical technique is sheet metal forming, which creates parts that account for a large percentage of the total vehicle weight. Many of these sheet metal parts make up the structure of the vehicle and are constructed from thin-walled tubes. To manufacture these thin-walled tubes into the desired shape, one of the main techniques is tube forming which can expand or reduce the tubes' diameters to the desired dimension. One specific tube forming technique is the flaring process which is typically performed at the tube end. In this paper, the tool rotation at its flaring axis was considered. The analysis of the expansion ratio, strain path, and failure limit was also performed along with experimentation. Frictional effects were considered. It was observed that varying the rotational speed of the flaring tool influenced the ability of the tube to flare. The expansion ratio can be maximized with a decreased amount of friction, a lower rotational speed of the flaring tool, and with an increase in tool velocity.

Original languageEnglish (US)
Article number012118
JournalIOP Conference Series: Materials Science and Engineering
Volume418
Issue number1
DOIs
StatePublished - Sep 21 2018
Event37th International Deep Drawing Research Group Conference - Forming of High Performance Sheet Materials and Components, IDDRG 2018 - Waterloo, Canada
Duration: Jun 3 2018Jun 7 2018

Fingerprint

Sheet metal
Metal forming
Automotive industry
Friction
Processing

All Science Journal Classification (ASJC) codes

  • Materials Science(all)
  • Engineering(all)

Cite this

@article{15103976b3d04583b4cc4aec56fa2737,
title = "Experimental investigation on tube flaring with a rotating tool",
abstract = "As the automotive industry becomes increasingly competitive, manufacturers are striving to design the lightest, most fuel-efficient vehicles to capture the market. To achieve this mission, the material processing techniques used in vehicle manufacturing must be investigated further. One such critical technique is sheet metal forming, which creates parts that account for a large percentage of the total vehicle weight. Many of these sheet metal parts make up the structure of the vehicle and are constructed from thin-walled tubes. To manufacture these thin-walled tubes into the desired shape, one of the main techniques is tube forming which can expand or reduce the tubes' diameters to the desired dimension. One specific tube forming technique is the flaring process which is typically performed at the tube end. In this paper, the tool rotation at its flaring axis was considered. The analysis of the expansion ratio, strain path, and failure limit was also performed along with experimentation. Frictional effects were considered. It was observed that varying the rotational speed of the flaring tool influenced the ability of the tube to flare. The expansion ratio can be maximized with a decreased amount of friction, a lower rotational speed of the flaring tool, and with an increase in tool velocity.",
author = "Mamros, {E. M.} and Nikhare, {Chetan P.}",
year = "2018",
month = "9",
day = "21",
doi = "10.1088/1757-899X/418/1/012118",
language = "English (US)",
volume = "418",
journal = "IOP Conference Series: Materials Science and Engineering",
issn = "1757-8981",
publisher = "IOP Publishing Ltd.",
number = "1",

}

Experimental investigation on tube flaring with a rotating tool. / Mamros, E. M.; Nikhare, Chetan P.

In: IOP Conference Series: Materials Science and Engineering, Vol. 418, No. 1, 012118, 21.09.2018.

Research output: Contribution to journalConference article

TY - JOUR

T1 - Experimental investigation on tube flaring with a rotating tool

AU - Mamros, E. M.

AU - Nikhare, Chetan P.

PY - 2018/9/21

Y1 - 2018/9/21

N2 - As the automotive industry becomes increasingly competitive, manufacturers are striving to design the lightest, most fuel-efficient vehicles to capture the market. To achieve this mission, the material processing techniques used in vehicle manufacturing must be investigated further. One such critical technique is sheet metal forming, which creates parts that account for a large percentage of the total vehicle weight. Many of these sheet metal parts make up the structure of the vehicle and are constructed from thin-walled tubes. To manufacture these thin-walled tubes into the desired shape, one of the main techniques is tube forming which can expand or reduce the tubes' diameters to the desired dimension. One specific tube forming technique is the flaring process which is typically performed at the tube end. In this paper, the tool rotation at its flaring axis was considered. The analysis of the expansion ratio, strain path, and failure limit was also performed along with experimentation. Frictional effects were considered. It was observed that varying the rotational speed of the flaring tool influenced the ability of the tube to flare. The expansion ratio can be maximized with a decreased amount of friction, a lower rotational speed of the flaring tool, and with an increase in tool velocity.

AB - As the automotive industry becomes increasingly competitive, manufacturers are striving to design the lightest, most fuel-efficient vehicles to capture the market. To achieve this mission, the material processing techniques used in vehicle manufacturing must be investigated further. One such critical technique is sheet metal forming, which creates parts that account for a large percentage of the total vehicle weight. Many of these sheet metal parts make up the structure of the vehicle and are constructed from thin-walled tubes. To manufacture these thin-walled tubes into the desired shape, one of the main techniques is tube forming which can expand or reduce the tubes' diameters to the desired dimension. One specific tube forming technique is the flaring process which is typically performed at the tube end. In this paper, the tool rotation at its flaring axis was considered. The analysis of the expansion ratio, strain path, and failure limit was also performed along with experimentation. Frictional effects were considered. It was observed that varying the rotational speed of the flaring tool influenced the ability of the tube to flare. The expansion ratio can be maximized with a decreased amount of friction, a lower rotational speed of the flaring tool, and with an increase in tool velocity.

UR - http://www.scopus.com/inward/record.url?scp=85054228323&partnerID=8YFLogxK

UR - http://www.scopus.com/inward/citedby.url?scp=85054228323&partnerID=8YFLogxK

U2 - 10.1088/1757-899X/418/1/012118

DO - 10.1088/1757-899X/418/1/012118

M3 - Conference article

AN - SCOPUS:85054228323

VL - 418

JO - IOP Conference Series: Materials Science and Engineering

JF - IOP Conference Series: Materials Science and Engineering

SN - 1757-8981

IS - 1

M1 - 012118

ER -