Abstract
Motorbike shock absorbers made with a closed die employ a tube-forming process that is more sensitive than that of a solid billet, because the tube is usually too thin-walled to conserve material. During tube forming, defects such as folding and cracking occur due to unstable tube forming and abnormal material flow. It is therefore essential to understand the relationship between the appearance of defects and the number of forming steps to optimize technological parameters. Based on both finite element method (FEM) simulations and microstructural observations, we demonstrate the important role of the number and methodology of the forming steps on the material flow, defects, and metal fiber anisotropy of motorbike shock absorbers formed from a thin-walled tube. We find limits of the thickness and height ratios of the tube that must be held in order to avoid defects. Our study provides an important guide to workpiece and processing design that can improve the forming quality of products using tube forming.
Highlights
Fabricated by Tube Forming in aTube forming in a closed die is a shaping method aimed at limiting highly unstable tube forming that produces folding defects in workpieces
The Qform V8.0.5 software was used for simulating the cold-forging effect on the microstructure of V8.0.5 the motorbike absorber fabricated the by tube forming effect in a closed
On the other hand, folding defects and microscopic cracks in the material often appear during the stamping process of the tube workpiece
Summary
Tube forming in a closed die is a shaping method aimed at limiting highly unstable tube forming that produces folding defects in workpieces This method of forming from a tubular workpiece has many advantages such as conservation of material, minimization of manufacturing labor, and, especially, the creation of metal fibers in parts that promote the mechanical properties of the product [1]. This method faces several challenges; while the level of deformation of the parts is not large, managing tube instability in the forming process is much more difficult than deforming with a normal workpiece. The influences of the internal pressure and axial feeding on the expansion and wall-thickness distribution during hot tube gas forming were investigated. The authors proposed that this method is effective for forming aluminum alloy tubes, and that the axial feeding is a vital parameter to prevent reductions in wall thickness [7]
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