Abstract
The paper presented a new method for forming flanges on hollow parts by incremental radial extrusion. In the classic process of radial extrusion, additional rings were used to limit the free flow of material in the radial direction. The flange was formed progressively, using rings of increasing diameters. The proposed method was verified by numerical analysis and experimental tests. The numerical calculations were performed by the finite element method using the Deform-3D software package. Tubes made of aluminum alloy EN AW 6060 were used as billets. Laboratory tests were carried out using the Instron 1000 HDX testing machine. The objective of the study was to determine the validity of the proposed flange extrusion method. Results demonstrated that the new method made it possible to produce flanges with a relatively large diameter and uniform thickness, confirming the effectiveness of the proposed forming technique.
Highlights
Hollow metal flanged parts can be produced using different manufacturing techniques.These techniques can be divided into three groups: casting, machining, and forming
From the point of view of material consumption, casting and forming processes are of great benefit because they allow for producing finished parts or semi-finished parts for further finishing at high material yield
The production of hollow parts is associated with many limitations that have been investigated in numerous studies, which has often led to the development of new techniques
Summary
Hollow metal flanged parts can be produced using different manufacturing techniques. These techniques can be divided into three groups: casting, machining, and forming. The selection of an appropriate method depends, among others, on the rate of production, material type, required product properties, and manufacturing costs. Additional advantages of metal forming methods include the possibility of obtaining products with higher strength properties than those of a billet material, high efficiency, and relatively low per-unit manufacturing costs [1]. There are manufacturing techniques that combine several different methods. The production of hollow parts is associated with many limitations that have been investigated in numerous studies, which has often led to the development of new techniques
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