PSI - Issue 68

Nagihan Erdem et al. / Structural Integrity Procedia 00 (2025) 000–000

Gunes Murat et al. / Procedia Structural Integrity 68 (2025) 653–659

659

4,6 4,8 5 5,2

4,8 5 5,2 5,4

4,6 4,8 5 5,2 5,4

100 150 200 250 300

100 150 200 250 300

100 150 200 250 300

Wall thickness (mm)

Distance (mm)

Distance (mm)

Distance (mm)

Wall thickness (mm) T750 R2 F1

T750 R2 F2

T750 R6 F1

T750 R6 F2

Wall thickness (mm) T750 R4 F1

T750 R4 F2

4,8 5 5,2 5,4

4,6 4,8 5 5,2

4,6 4,8 5 5,2

100 150 200 250 300

100 150 200 250 300

100 150 200 250 300

Distance (mm)

Distance (mm)

Distance (mm)

T1100 R2 F1 T1100 R2 F2

T1100 R4 F1 T1100 R4 F2

T1100 R6 F1 T1100 R6 F2

Wall thickness (mm)

Wall thickness (mm)

Wall thickness (mm)

Fig. 9. Influence of roller geometry on the wall thickness

Conclusion In this study, a well-founded finite element model was established in FORGE® to make a prediction regarding the effect of the temperature, reduction ratio and roller geometry on the wall thickness. As an auxiliary finding, the impacts of these parameters were also observed on the force in the y-axis. According to the analysis results, it was observed that as the temperature increased, the increase in wall thickness decreased, and the force in the y-axis direction decreased by almost half. Another observed parameter, the reduction ratio, has a directly proportional effect on the wall thickness. In other words, the thickening was greatest in cases where the reduction ratio was highest. As the reduction ratio increases, the amount of deviation from the ideal geometry also increases, the quality of the desired geometry is not achieved. It was observed that the roller geometry changed the thickening character in the end region of the part. If a roller with a larger forming zone radius is used, the thickness of the end zone gradually decreases. It would be very worthwhile to test the results of the analysis with the real process. It is planned that this will definitely be done in future studies as an extended version of this research. References Alberti, N., Cannizzaro, L., Valvo, E. L., Micari, F., 1989. Analysis Of Metal Spinning Processes By The Adina Code. Comput Struct. 32, 517– 525. https://doi.org/10.1016/0045-7949(89)90343-X. Erkorkmaz, K., Altintas, Y., 2001. High-speed CNC system design. Part I: jerk limited trajectory generation and quintic spline interpolation. Int. J. Mach. Tools Manuf. 41. https://doi.org/10.1016/S0890-6955(01)00002-5. FORGE® Documentation- Part 5 Process Data, 2018. Hashmi, M. S. J., 2014. Hot Tube-Forming, in: Hashmi, S., Van Tyne, C. J., Batalha, G. F., Yilbas, B. (Eds.), Comprehensive Materials Processing, Elsevier, Colorado, pp. 326. Hua, F. A., Zhang, Y. N., Guo, M. H., Guo, D. Y., Tong, W. H., Hu, Z. Q., 2005. Three-dimensional finite element analysis of tube spinning. J. Mater. Process. 168, 68–74. https://doi.org/10.1016/j.jmatprotec.2004.10.014. Masory, O., Koren, Y., 1982. Reference-Word Circular Interpolators for CNC Systems. J. Eng. Ind. 104. Mutlu, M., Ozsoy, A., Fenercioglu, T. O., Karakas, A., Baydogan, M., 2023. Effect of reduction ratio in flow forming process on microstructure and mechanical properties of a 6082 Al alloy. In: Proceedings of the 26th International ESAFORM Conference on Material Forming: ESAFORM 2023, pp. 1015. https://doi.org/10.21741/9781644902479-111. Zhan, M., Yang, H., Guo, J., Wang, X., 2005. Review on hot spinning for difficult to deform lightweight metals. TNMSC 25, 1732–1743. https://doi.org/10.1016/S1003-6326(15)63778-5. Zoghi, H., Arezoodar, A. F., Sayeaftabi, M., 2013. Enhanced finite element analysis of material deformation and strain distribution in the spinning of 42CrMo steel tubes at elevated temperature. Mater. Des. 47, 234–242. https://doi.org/10.1016/j.matdes.2012.11.049.