DOI: https://doi.org/10.32515/2664-262X.2025.11(42).1.121-128
Deformation of Hollow Forgings of The Sleeve Type in the Process Of Drawing Without a Mandrel by Beveled Punches
About the Authors
Oleh Markov, Professor, Doctor in Technics (Doctor of Technic Sciences), Donbas State Engineering Academy, Kramatorsk-Ternopil, Ukraine, e-mail: oleg.markov.omd@gmail.com, ORCID ID: 0000-0001-9377-9866
Yevhen Muzykin, Master's degree, Dnipro electrical and mechanical plant LLC, Dnipro, Ukraine, e-mail: metalworkingplant@gmail.com, ORCID ID: 0009-0004-7685-4392
Pavlo Muzykin, Master's degree, Dnipro electrical and mechanical plant LLC, Dnipro, Ukraine, e-mail: metalworkingplant@gmail.com, ORCID ID: 0009-0000-7490-3219
Abstract
The purpose of the work is to increase the efficiency of the processes of deformation of hollow cylindrical blanks without a mandrel by means of scientifically substantiated design of their deformation modes based on the created numerical models, which allow developing and evaluating a new technological process for the deformation of such forgings. The new technological process of deformation will increase the competitiveness of domestic products, which will allow increasing the volume of exports of unique products on the foreign market. The article develops a new technological process for the deformation of forgings of the type of long sleeves with rhombic strikers with slopes. The study of the deformation process made it possible to clarify the regularities of the shape change of the hollow blank for the new technological process. The angles of the cutouts and slopes of the strikers (10°, 20° and 30°) and the length of the workpiece feed into the strikers were studied. At feeds equal to 0.1D and a cut angle of rhombic punches of 115°, the minimum closing of the hole of the hollow workpiece takes place. The effective geometry of the deforming tool to increase the extraction coefficient when deforming hollow sleeves should be rhombic punches with a bevel slope of 10...20° and a feed length of the workpiece b/D=0.1. The curvature of the end face of the hole is equal to the allowance for machining, which ensures obtaining the required dimensions and shape of the forging without using a mandrel. Based on the results of a theoretical study of the mechanism of forging the cylinder hole, an effective scheme was selected to ensure minimum forging of the hole, in which the cutout punches had a cut with an angle of 115° and a width of the deforming part of 0.1D. The general pattern for the studied deformation schemes is that the intensity of hole deformation is the same for different crimps with constant ratios of the workpiece sizes. At feeds greater than 0.2D, there is no qualitative or quantitative change in the degree and intensity of hole forging. This allows us to determine the recommended feed for intensive drawing of the workpiece and reducing the degree of hole forging. The recommended feed should be in the range (0.1...0.2)D.
Keywords
deformation, internal hole, broaching, FEM, deformations, mandrel
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References
1. Zhu Baiqing, Lu Haixing, Tong Yifei, Li Dongbo, Xia Yong. (2015). Research on Charging Combination Based on Batch Weight Fit Rule for Energy Saving in Forging. Mathematical Problems in Engineering, Article ID 531756. 9 pages. http://dx.doi.org/10.1155/2015/531756.
2. Askelianets, А. (2014). Analysis of theoretic research of the ring tapered tool penetration with subsequent upsetting in the lining ring while manufacturing a disc with shoulder. Metallurgical and Mining Industry, 4. 70–75.
3. Yunjian Wu, Xianghuai Dong, Qiong Yu. (2015). Upper bound analysis of axial metal flow inhomogeneity in radial forging process. International Journal of Mechanical Sciences, 93, 102–110.
4. Sizek, H. W. (1995). Radial Forging. Metalworking: Bulk Forming, 178.
5. Ghaei, А. Movahhedy, M. R., Karimi Taheri A. (2008). Finite element modelling simulation of radial forging of tubes without mandrel. Materials & Design, 29, 867–872.
6. Fan, L., Wang Z., Wang H. (2014). 3D finite element modeling and analysis of radial forging processes. Journal of Manufacturing Processes, 16, 329–334.
7. Burkin, S. P. et al. (1996). A vertical automated forging center for the plastic deformation of continuouslycast ingots. Journal of Materials Processing Technology, 58, 170–173.
8. Zhang, Q., et al. (2014). Rotary swaging forming process of tube workpieces. 11th International Conference on Technology of Plasticity, ICTP 2014. October 2014. Nagoya Congress Center, Nagoya, Japan. Procedia Engineering, N 81, pp. 2336–2341.
9. Sanjari, M., et al. (2012). Determination of strain field and heterogeneity in radial forging of tube using finite element method and microhardness test. Materials and Design, 38, 147–153.
10. Wang, Z. G. (2011). The theory analysis and numerical simulation for the radial forging process of gun barrel. Nanjing University of Science and Technology, 14, 28–30.
11. Knauf, F., et al. (2011). Latest Development in Railway Axle and ThickWalled Tube forging on a Hydraulic Radial Forging Machine Type SMX. 18th International Forgemasters Meeting. Market and Technical Proceedings. Pittsburgh, PA, USA. September 12–15, 215–220.
12. Koppensteiner, R. Tang, Z. (2011). Optimizing Tooling And Pass Design For Effectiveness On Forged Product. 18th International Forgemasters Meeting. Market and Technical Proceedings. Pittsburgh, PA, USA. September 12–15, 225–229.
13. Sheu, J.J., Lin, SuYi., Yu, C. H. (2014). Optimum die design for single pass steel tube drawing with large strain deformation. 11th International Conference on Technology of Plasticity. ICTP 2014. 1924 October 2014. Nagoya Congress Center, Nagoya, Japan. Procedia Engineering, 81, 688–693.
14. Jaouen, О., et al. (2011). From Hollow Ingot to Shell with a Powerful Numerical Simulation Software Tool. 18th International Forgemasters Meeting. Market and Technical Proceedings. Pittsburgh. PA. USA. September 12–15, pp. 513–518.
15. Li ,Y., et al. (2013). Numerical simulation and experimental study on the tube sinking of a thinwalled copper tube with axially inner micro grooves by radial forging. Journal of Materials Processing Technology, 213, 987–996.
Citations
1. Research on Charging Combination Based on Batch Weight Fit Rule for Energy Saving in Forging / Zhu Baiqing, Lu Haixing, Tong Yifei, Li Dongbo, Xia Yong. Mathematical Problems in Engineering. 2015. Article ID 531756. 9 pages. http://dx.doi.org/10.1155/2015/531756.
2. Askelianets, А. Analysis of theoretic research of the ring tapered tool penetration with subsequent upsetting in the lining ring while manufacturing a disc with shoulder. Metallurgical and Mining Industry. 2014. № 4. С. 70–75.
3. Wu, Y. Upper bound analysis of axial metal flow inhomogeneity in radial forging process / Yunjian Wu, Xianghuai Dong, Qiong Yu. International Journal of Mechanical Sciences. 2015. N 93. Р. 102–110.
4. Sizek, H. W. Radial Forging. Metalworking : Bulk Forming. 2005. P. 172–178.
5. Ghaei, А. Finite element modelling simulation of radial forging of tubes without mandrel / А. Ghaei, M. R. Movahhedy, A. Karimi Taheri. Materials & Design. 2008. № 29. P. 867–872.
6. Fan, L. 3D finite element modeling and analysis of radial forging processes / Lixia Fan, Zhigang Wang, He Wang. Journal of Manufacturing Processes. 2014. N 16. Р. 329–334.
7. A vertical automated forging center for the plastic deformation of continuouslycast ingots / S. P. Burkin, E. A. Korshunov , V. L. Kolmogorov, N. A. Babailov, V. M. Nalesnik. Journal of Materials Processing Technology. 1996. № 58. P. 170–173.
8. Rotary swaging forming process of tube workpieces / Qi Zhang, Kaiqiang Jin, Dong mu, Pengju Ma, Jie Tian. 11th International Conference on Technology of Plasticity, ICTP 2014. October 2014. Nagoya Congress Center, Nagoya, Japan. Procedia Engineering. 2014. N 81. Р. 2336–2341.
9. Determination of strain field and heterogeneity in radial forging of tube using finite element method and microhardness test / M. Sanjari, P. Saidi, A. Karimi Taheri, M. HosseinZadeh. Materials and Design. 2012. N 38. Р. 147–153.
10. Wang, Z. G. The theory analysis and numerical simulation for the radial forging process of gun barrel / Z. G. Wang. Nanjing University of Science and Technology. 2011. Р. 28–30.
11. Latest Development in Railway Axle and ThickWalled Tube forging on a Hydraulic Radial Forging Machine Type SMX / Frederik Knauf, PaulJosef Nieschwitz, Albrecht Holl, Hans Pelster, Rolf Vest. 18th International Forgemasters Meeting. Market and Technical Proceedings. Pittsburgh, PA, USA. September 12–15. 2011. Р. 215–220.
12. Koppensteiner, R. Optimizing Tooling And Pass Design For Effectiveness On Forged Product / Robert Koppensteiner, Zack Tang. 18th International Forgemasters Meeting. Market and Technical Proceedings. Pittsburgh, PA, USA. September 12–15. 2011. Р. 225–229.
13. Sheu, J.J. Optimum die design for single pass steel tube drawing with large strain deformation / JinnJong Sheu, SuYi Lin, ChengHsien Yu. 11th International Conference on Technology of Plasticity. ICTP 2014. 1924 October 2014. Nagoya Congress Center, Nagoya, Japan. Procedia Engineering. 2014. N 81. Р. 688–693.
14. Jaouen, О. From Hollow Ingot to Shell with a Powerful Numerical Simulation Software Tool / О. Jaouen, F. Costes, P. Lasne, M. Barbelet. 18th International Forgemasters Meeting. Market and Technical Proceedings. Pittsburgh. PA. USA. September 12–15. 2011. Р. 513–518.
15. Li ,Y. Numerical simulation and experimental study on the tube sinking of a thinwalled copper tube with axially inner micro grooves by radial forging / Yong Li, Ting He, Zhixin Zeng. Journal of Materials Processing Technology. 2013. N 213. Р. 987–996.
Copyright (c) 2025 Oleh Markov, Yevhen Muzykin, Pavlo Muzykin
Deformation of Hollow Forgings of The Sleeve Type in the Process Of Drawing Without a Mandrel by Beveled Punches
About the Authors
Oleh Markov, Professor, Doctor in Technics (Doctor of Technic Sciences), Donbas State Engineering Academy, Kramatorsk-Ternopil, Ukraine, e-mail: oleg.markov.omd@gmail.com, ORCID ID: 0000-0001-9377-9866
Yevhen Muzykin, Master's degree, Dnipro electrical and mechanical plant LLC, Dnipro, Ukraine, e-mail: metalworkingplant@gmail.com, ORCID ID: 0009-0004-7685-4392
Pavlo Muzykin, Master's degree, Dnipro electrical and mechanical plant LLC, Dnipro, Ukraine, e-mail: metalworkingplant@gmail.com, ORCID ID: 0009-0000-7490-3219
Abstract
Keywords
Full Text:
PDFReferences
1. Zhu Baiqing, Lu Haixing, Tong Yifei, Li Dongbo, Xia Yong. (2015). Research on Charging Combination Based on Batch Weight Fit Rule for Energy Saving in Forging. Mathematical Problems in Engineering, Article ID 531756. 9 pages. http://dx.doi.org/10.1155/2015/531756.
2. Askelianets, А. (2014). Analysis of theoretic research of the ring tapered tool penetration with subsequent upsetting in the lining ring while manufacturing a disc with shoulder. Metallurgical and Mining Industry, 4. 70–75.
3. Yunjian Wu, Xianghuai Dong, Qiong Yu. (2015). Upper bound analysis of axial metal flow inhomogeneity in radial forging process. International Journal of Mechanical Sciences, 93, 102–110.
4. Sizek, H. W. (1995). Radial Forging. Metalworking: Bulk Forming, 178.
5. Ghaei, А. Movahhedy, M. R., Karimi Taheri A. (2008). Finite element modelling simulation of radial forging of tubes without mandrel. Materials & Design, 29, 867–872.
6. Fan, L., Wang Z., Wang H. (2014). 3D finite element modeling and analysis of radial forging processes. Journal of Manufacturing Processes, 16, 329–334.
7. Burkin, S. P. et al. (1996). A vertical automated forging center for the plastic deformation of continuouslycast ingots. Journal of Materials Processing Technology, 58, 170–173.
8. Zhang, Q., et al. (2014). Rotary swaging forming process of tube workpieces. 11th International Conference on Technology of Plasticity, ICTP 2014. October 2014. Nagoya Congress Center, Nagoya, Japan. Procedia Engineering, N 81, pp. 2336–2341.
9. Sanjari, M., et al. (2012). Determination of strain field and heterogeneity in radial forging of tube using finite element method and microhardness test. Materials and Design, 38, 147–153.
10. Wang, Z. G. (2011). The theory analysis and numerical simulation for the radial forging process of gun barrel. Nanjing University of Science and Technology, 14, 28–30.
11. Knauf, F., et al. (2011). Latest Development in Railway Axle and ThickWalled Tube forging on a Hydraulic Radial Forging Machine Type SMX. 18th International Forgemasters Meeting. Market and Technical Proceedings. Pittsburgh, PA, USA. September 12–15, 215–220.
12. Koppensteiner, R. Tang, Z. (2011). Optimizing Tooling And Pass Design For Effectiveness On Forged Product. 18th International Forgemasters Meeting. Market and Technical Proceedings. Pittsburgh, PA, USA. September 12–15, 225–229.
13. Sheu, J.J., Lin, SuYi., Yu, C. H. (2014). Optimum die design for single pass steel tube drawing with large strain deformation. 11th International Conference on Technology of Plasticity. ICTP 2014. 1924 October 2014. Nagoya Congress Center, Nagoya, Japan. Procedia Engineering, 81, 688–693.
14. Jaouen, О., et al. (2011). From Hollow Ingot to Shell with a Powerful Numerical Simulation Software Tool. 18th International Forgemasters Meeting. Market and Technical Proceedings. Pittsburgh. PA. USA. September 12–15, pp. 513–518.
15. Li ,Y., et al. (2013). Numerical simulation and experimental study on the tube sinking of a thinwalled copper tube with axially inner micro grooves by radial forging. Journal of Materials Processing Technology, 213, 987–996.
Citations
1. Research on Charging Combination Based on Batch Weight Fit Rule for Energy Saving in Forging / Zhu Baiqing, Lu Haixing, Tong Yifei, Li Dongbo, Xia Yong. Mathematical Problems in Engineering. 2015. Article ID 531756. 9 pages. http://dx.doi.org/10.1155/2015/531756.
2. Askelianets, А. Analysis of theoretic research of the ring tapered tool penetration with subsequent upsetting in the lining ring while manufacturing a disc with shoulder. Metallurgical and Mining Industry. 2014. № 4. С. 70–75.
3. Wu, Y. Upper bound analysis of axial metal flow inhomogeneity in radial forging process / Yunjian Wu, Xianghuai Dong, Qiong Yu. International Journal of Mechanical Sciences. 2015. N 93. Р. 102–110.
4. Sizek, H. W. Radial Forging. Metalworking : Bulk Forming. 2005. P. 172–178.
5. Ghaei, А. Finite element modelling simulation of radial forging of tubes without mandrel / А. Ghaei, M. R. Movahhedy, A. Karimi Taheri. Materials & Design. 2008. № 29. P. 867–872.
6. Fan, L. 3D finite element modeling and analysis of radial forging processes / Lixia Fan, Zhigang Wang, He Wang. Journal of Manufacturing Processes. 2014. N 16. Р. 329–334.
7. A vertical automated forging center for the plastic deformation of continuouslycast ingots / S. P. Burkin, E. A. Korshunov , V. L. Kolmogorov, N. A. Babailov, V. M. Nalesnik. Journal of Materials Processing Technology. 1996. № 58. P. 170–173.
8. Rotary swaging forming process of tube workpieces / Qi Zhang, Kaiqiang Jin, Dong mu, Pengju Ma, Jie Tian. 11th International Conference on Technology of Plasticity, ICTP 2014. October 2014. Nagoya Congress Center, Nagoya, Japan. Procedia Engineering. 2014. N 81. Р. 2336–2341.
9. Determination of strain field and heterogeneity in radial forging of tube using finite element method and microhardness test / M. Sanjari, P. Saidi, A. Karimi Taheri, M. HosseinZadeh. Materials and Design. 2012. N 38. Р. 147–153.
10. Wang, Z. G. The theory analysis and numerical simulation for the radial forging process of gun barrel / Z. G. Wang. Nanjing University of Science and Technology. 2011. Р. 28–30.
11. Latest Development in Railway Axle and ThickWalled Tube forging on a Hydraulic Radial Forging Machine Type SMX / Frederik Knauf, PaulJosef Nieschwitz, Albrecht Holl, Hans Pelster, Rolf Vest. 18th International Forgemasters Meeting. Market and Technical Proceedings. Pittsburgh, PA, USA. September 12–15. 2011. Р. 215–220.
12. Koppensteiner, R. Optimizing Tooling And Pass Design For Effectiveness On Forged Product / Robert Koppensteiner, Zack Tang. 18th International Forgemasters Meeting. Market and Technical Proceedings. Pittsburgh, PA, USA. September 12–15. 2011. Р. 225–229.
13. Sheu, J.J. Optimum die design for single pass steel tube drawing with large strain deformation / JinnJong Sheu, SuYi Lin, ChengHsien Yu. 11th International Conference on Technology of Plasticity. ICTP 2014. 1924 October 2014. Nagoya Congress Center, Nagoya, Japan. Procedia Engineering. 2014. N 81. Р. 688–693.
14. Jaouen, О. From Hollow Ingot to Shell with a Powerful Numerical Simulation Software Tool / О. Jaouen, F. Costes, P. Lasne, M. Barbelet. 18th International Forgemasters Meeting. Market and Technical Proceedings. Pittsburgh. PA. USA. September 12–15. 2011. Р. 513–518.
15. Li ,Y. Numerical simulation and experimental study on the tube sinking of a thinwalled copper tube with axially inner micro grooves by radial forging / Yong Li, Ting He, Zhixin Zeng. Journal of Materials Processing Technology. 2013. N 213. Р. 987–996.