Tube branching by asymmetric compression beading

This paper draws on the capability of producing out-of-plane instability waves in thin-walled tubes subjected to axial loading. In terms of deformation mechanics, the aim is to identify the operative parameters, to diagnose possible sources of failure and to understand the route for selecting the most appropriate operative conditions for obtaining sound asymmetric compression beads created by out-of-plane instability waves.In terms of industrial technology, the goal is to apply the fundamentals of asymmetric compression beading for developing an innovative tube branching process to join tubes that is capable of eliminating welding and brazing in standard or user made types of connections.The presentation includes details on tool design, independent determination of the mechanical properties of the tubes, finite element modelling and experimentation under laboratory conditions. Results and observations show that tube branching by means of asymmetric compression beading is a flexible and cost-effective technology for joining tubes in standard tee connections as well as in special purpose applications involving custom sizes and dissimilar materials.     

End-to-end joining of tubes by plastic instability

This paper presents an innovative joining process for the longstanding challenge of connecting two tubes by their ends at room temperature by means of a simple, effective and environmental friendly solution. The process is performed in one stroke and makes use of tube expansion to put the mating surfaces of the two tubes in a correct position for subsequent locking by means of plastic instability and simultaneous compression beading.The presentation combines experimentation with commercial S460MC (carbon steel) welded tubes and finite element modelling with the purpose of characterizing the deformation mechanics of the process, identifying its major operating parameters and providing basic design guidelines to successfully perform the end-to-end joining of tubes by plastic instability. The new proposed joining process has potential to easily and efficiently replace existing solutions based on the utilization of fastened, crimped, welded, brazed or adhesive joints.     

Effects of current frequency on electromagnetic tube compression

Current frequency is one of the most important parameters that must be analyzed and optimized for the analysis and design of electromagnetic forming process, and its effects on the electromagnetic forming process are very complicated. The influence of frequency on electromagnetic tube compression has been investigated by means of the sequential coupling numerical simulation. The delaying and the total time of the forming process prolong with the lowering of the frequency, and the optimum frequency is found that corresponds to the largest deformation and the greatest plastic strain energy of the tube. There is a special range around the optimum frequency, where the corresponding deformations are similar and the relative skin depth is between 0.61 and 0.70. The maximum energy efficiency of the electromagnetic tube compression is 13.76% in this work, which is corresponding to the optimum frequency.     

管材内压液力成形的稳定性分析

管材内压液力成形过程中 ,管坯在内压与轴向压力的共同作用下发生变形。成形过程中常见的缺陷是起皱和破裂 ,这两种缺陷的产生都和管的失稳有关。本文运用薄膜理论分析了管坯在轴向力单独作用下的压缩失稳 ,得出临界轴向压力的计算公式 ;从失稳应变强度入手 ,分析了圆柱管在内压和轴向压力共同作用下的分散性失稳 ,根据失稳应变强度的计算公式 ,分析了应力状态系数 a、厚向异性指数 rh、应变强化指数 n等因素对管的失稳应变强度的影响规律     

Sequential coupling simulation for electromagnetic–mechanical tube compression by finite element analysis

A sequential coupled field analysis of electromagnetic tube compression process has been performed by using the finite element method (FEM). A 2D axisymmetric electromagnetic model based on the magnetic vector potential is proposed for the calculation of magnetic field and magnetic forces; and Newmark integration method is used to calculate the dynamic plastic deformation of tube in the mechanical model. In each time step during the simulation, the transient magnetic forces acting on the tube are obtained from the electromagnetic model, which are then used as input load to the mechanical model. According to the tube deformation calculated, the geometry of the electromagnetic model is updated. Therefore, the sequential coupling simulation is realized between the electromagnetic model and the mechanical model, whose results are more accurate than the loosing coupling simulation method. The radial deformation along the outer generatrix of deformed tube wall is presented as a function of time and the plastic strain energy of electromagnetic tube compression is analyzed.     

Cold welding sealing of copper-water micro heat pipe ends

The quality of micro heat pipe(MHP) is strongly affected by sealing technology. Based on the analysis of requirements of sealing technology, a cold welding technology was presented to seal MHP. In the cold welding process, compression force was used to flatten micro groove copper(MGC) tube. Then the bonding of MGC tube was reached because of intensively plastic deformation of MGC tube under pressure. It is found that the plastic deformation area of the cold welding of MGC tube can be divided into three sections. The deformation of micro grooves in each section was investigated; the influence of the dimensions of cylindrical heads on the weld joint shape and strength was studied; and a comparison between smooth copper tube and MGC tube was done. The results show that a groove compression stage exists in the cold welding of MGC tube besides a flattened stage and a melting stage.     

基于冲击屈曲能量准则的磁脉冲缩径塑性失稳判据

磁脉冲成形是利用磁压力对金属坯料进行塑性加工的高能、高速率加工方法,与常规成形工艺相比有诸多优点,为高强度、难成形材料开辟了新的成形加工途径。而瞬时近似正弦衰减的脉冲磁压力和不均匀起皱变形,使圆管磁脉冲缩径压缩失稳判据研究非常棘手。文章选择王仁提出的冲击屈曲能量准则进行此塑性屈曲判据研究。首先,应用该能量准则确定冲击载荷作用下圆管产生塑性屈曲的临界冲击能量;然后,通过使临界冲击能量与磁压力脉冲第一波对工件变形和运动做功相等,建立圆管产生径向塑性压缩失稳的临界判据。研究表明,产生径向屈曲塑性变形的临界放电电压随径厚比增加而提高,其试验值与判据确定的理论值吻合较好。应用该判据能够预测使圆管产生失稳屈曲的临界放电电压(能量),使均匀径向塑性变形的定量分析成为可能。     

Deformation characteristic of semi-solid ZCuSn10 copper alloy during isothermal compression

The compression tests were carried out by Gleeble-1500 thermo-mechanical simulator with samples of semi-solid ZCuSn10 alloy prepared by strain-induced melt activation(SIMA) process. The original microstructure and the deformation temperature of semi-solid ZCuSn10 alloy are different. The strain is 0.2, and the strain rate is 1 s~(-1) for the compression test. The results show that when the semi-solid ZCuSn10 alloy was prepared by SIMA process, the liquid fraction of semi-solid microstructure increases, and the solid grain is smaller,more uniform and more inclined to be round as the rolling pre-deformation increasing. The results also indicate that the deformation resistance of ZCuSn10 alloy in semi-solid state decreases with the deformation temperature increasing or the solid fraction of original microstructure decreasing. The stress–strain curves of the isothermal compression can be divided into quasi-elastic deformation stage and plastic deformation stage, and there are three deformation zones in the samples after isothermal compression, namely the difficult deformation zone, the large deformation zone and the free deformation zone. In the three deformation zones, the main deformation mechanism is flow of liquid incorporating solid particles(FLS)mechanism, plastic deformation of solid particles(PDS)mechanism and liquid flow(LF) combining with FLS mechanism, respectively.     

SEVERE PLASTIC DEFORMATION TECHNIQUES

1.~onTheinterestindevelopmentoftiltwhnegrainsizeincreasedinrecentyearsforlowtemperaturehighstrainratesuperplasticityofaluminumalloysandsuperstrongsteelswithoutlossoftoughness.Theultimatendcrostmctureinaspecimenisdetendnedlargelybytheflowpatternsduringstrain.Whenlargestrainisused(morethan3),multipleflowpatternsusuallyoccurexceptfortorsion.Thesemtiltipleflowpatternsareobtainedbychangingthedirectionofdeformation.Normalplanestrainhasasingledirectionofdeformationandistypicallylimitedtoamaximumstrai…     

粉末烧结钨合金材料的绝热剪切变形局域化实验研究

在分离式Ｈｏｐｋｉｎｓｏｎ压杆装置上对斜圆柱粉末烧结钨合金试件进行了冲击实验,实验中观察到试件的宏观破断现象;用光学和扫描电子显微镜观察到钨合金中出现绝热剪切带这一变形局域化现象。实验结果表明,钨颗粒的形状和空间取向对钨合金剪切变形形式有明显的影响。     

Ti-6Al-2Zr-1Mo-1V合金塑性流动失稳预测

对Ti-6Al-2Zr-1Mo-1V合金进行等温恒应变速率压缩试验,利用压缩试验数据对比Prasad失稳准则和唯象型失稳准则,发现2种准则均预测出合金在应变速率为0.32~10 s-1范围内的塑性流动失稳现象,该失稳区随变形温度的降低具有逐渐向低应变速率范围扩展的趋势。经微观组织观察发现,Prasad准则不能预测到合金在750~800 ℃,0.001~0.0032 s-1范围发生的局部流动和弯折失稳,而唯象型准则对合金在770~870 ℃、0.01~0.32 s-1和900~950 ℃、0.32~3.16 s-1区域出现的晶界裂纹、孔洞以及局部流动不能进行准确预测。结合2种准则的优缺点,提出预测合金塑性流动失稳的新方法。     

Evaluation of effect of flow stress characteristics of tubular material on forming limit in tube hydroforming process

The material properties for the analytical and numerical simulation in sheet metal processes, especially in tube hydroforming process, are generally obtained from the uniaxial tensile test of raw sheet material. However, the validation of the formability and reliability of the numerical simulation for the tube hydroforming process arises from the fact that the material characteristics of tubes are different from those of the raw sheet materials. In order to determine the most suitable material property of the tubular material for the evaluation of forming limit on the THF process, the uniaxial tensile test for the specimens of the raw sheet metal and the roll-formed tube and the free bulge test for the roll-formed tubular material are carried out in this paper. The forming limit curves are also derived using plastic instability based on three kinds of necking criteria, which are Hill’s local necking criterion for sheet and Swift’s diffuse necking criteria for sheet and tube, to describe and explain the forming limits for the roll-formed tubular material in the THF process. In order to acquire the informative data on the forming limit curves in the THF process, the loading condition of the free bulge test is controlled. The proper band from nearly necking initiation to nearly bursting initiation has been defined for the roll-formed tubular material in the THF process. It can be concluded that the flow stress of the tubular material should be determined from the actual free bulge test to find the practically valuable forming limit curve for the THF process.     

Forming of thin-walled hollow spheres using sacrificial polymer mandrels

This paper introduces a novel type of mandrels (sacrificial polymer mandrels) that is expected to enlarge the tube forming window of very slender preforms by diminishing the risk of wrinkling and plastic instability. The overall feasibility of the concept is demonstrated by means of a pre-industrial test case consisting of single-stage nosing of hollow spheres for gas storage applications.Numerical modelling based on independently determined mechanical properties of the materials and executed on an innovative extension of the finite element flow formulation for metal–polymer cold forming applications is performed with the purpose of identifying the most important process parameters and understanding their influence in the overall formability.Results show the adequacy of using sacrificial polymer mandrels for the small-batch and low-cost production of thin-walled hollow spheres and, because the novel type of mandrels can easily be extended to other tube forming operations, it effectively contributes to transferable technological knowledge.     

薄壁大直径不锈钢管的弯曲成形研究

本文主要针对薄壁大直径不锈钢管在数控弯管机成形过程中发生的多种失稳起皱、断裂等问题进行剖析,并针对各种复杂情况设计不同材料的模具,制作出适合大批量生产的工装模具。     

Analysis of plastic instability during sandwich sheet rolling

In this study, plastic instability occurring in the hard inner layer during symmetrical sandwich sheet rolling was investigated. Two criteria for diffusion necking and local necking under a tri-axial stress state were developed to predict the occurrence of plastic instability in the hard inner layer during sandwich sheet rolling. Stress states in the inner hard layer at the exit of the roll-gap, where plastic instability is most likely to occur, were employed to formulate the plastic instability criteria. The effects of various rolling conditions such as the thickness ratio of sheets, yield shear stress ratio of sheets, etc. upon the critical thickness reduction, under which plastic instability can be avoided, were discussed systematically. Furthermore, experiments on sandwich sheet rolling were also conducted by employing aluminum and mild steel as layers of sandwich sheets. It was found that the theoretical predictions of the critical reduction were in good agreement with the experimental measurements. Throughout the study, it is clear that the proposed plastic instability criteria are able to offer useful knowledge in designing the pass-schedule of sandwich sheet rolling processes.     

An instability index of shear band for plasticity in metallic glasses

Catastrophic failure along a dominant shear band sets the limit on how much plasticity can be achieved in metallic glasses (MGs) under uniaxial compression. Here we show that this instability process is governed by a single system parameter, called the shear-band instability index (SBI), which is proportional to sample size and inversely proportional to machine stiffness. We provide extensive experimental proof of this concept by conducting a series of tests with a range of controlled values of sample size and machine stiffness. The theory of SBI has led us to a more comprehensive understanding of the mechanisms of plastic deformation in MGs via simultaneous operation of multiple shear bands versus a single dominant one. This concept provides a theoretical basis to design systems which promote plasticity/ductility in MGs by suppressing or delaying shear-band instability.     

Effect of deformation geometry on the intermittent plastic flow associated with the Portevin–Le Chatelier effect

The unstable plastic flow caused by the Portevin–Le Chatelier effect is studied experimentally. Non-local effects due to strain heterogeneity are addressed by comparing the statistical and multifractal properties of tension and compression deformation curves of an AlMg alloy. Power-law statistical distributions and multifractal scaling are found in certain experimental conditions, and provide a quantitative characterization of the plastic-flow intermittency. The analysis reveals distinct temporal patterns associated with stress serrations in tension and compression, reflecting distinct modes of the collective dislocation dynamics. In contrast, the onset of instability follows similar relationships in both loading conditions. This similarity justifies the conventional approach to modeling the loss of stability of a uniform plastic flow as a local property, governed by the homogenized behavior of the dislocation ensemble.     

Deformation characteristics during Y-shaped tube hydroforming of 6061 aluminum alloy

To manufacture lightweight tube components for aerospace oil circuit systems, an experiment was run to investigate the deformation characteristics on Y-shaped tube hydroforming of 6061 aluminum alloy. Both strain state and metallurgical structure indicate that there are four kinds of prevailing defects during Y-shaped tube hydroforming: bursting, lack of cylindricity, wrinkling, and thinning due to the poor plastic property of 6061 aluminum alloy. The danger of bursting prevails at the early stage of the operation as a result of excessively high internal pressure. In contrast, wrinkling prevails after the middle stage of the operation as a result of excessively axial feeding and cannot be eliminated during subsequent deformation. Lack of cylindricity is mainly because of insufficient axial feeding and internal pressure but can be eliminated by increasing internal pressure. Elongation and compression deformations are originated on protrusion and main pipe of Y-shape tube respectively all the way through the bulging process. Consequently, minimum and maximum thicknesses are at the top of protrusion and the bottom of Y-shape tube respectively, which induces a V-shape borderline of thickness distribution. According to the excessive plastic deformation, microstructure evolution is originated. Crystal grain of protrusion is elongated and its grain size is about 150 μm. In contrast, crystal grain of the middle zone of main tube is refined greatly, which grain size is 50 μm, decreased by 75%. These are useful to improve the component.     

薄壁管管端成形的有限元分析

针对管端成形过程中金属塑性流动引起的轴向伸缩及卸载回弹导致的成形精度问题,研究金属的塑性流动和回弹对管端成形的影响。以不锈钢卡压式直通管件为研究对象,运用LS-DYNA的有限元显式算法和隐式算法对薄壁管管端成形进行数值模拟,得到管材的金属流动分布和卸载后的回弹结果,并进行了实验验证。研究表明,管端扩孔和缩孔中,在变形急剧处,金属出现一定程度的累积,壁厚有较明显地增加。金属的流动对管端的径向尺寸影响可以忽略,但是对管端的轴向尺寸影响较大,需对坯料进行补偿;管端卸载后的回弹尺寸影响成形的精度,需通过模具进行补偿。对金属塑性流动和回弹进行有限元分析,能有效地指导管端成形的模具设计及优化加工工艺,极大缩短产品开发和模具设计周期。