Research Papers

Novel Friction-Assisted Tube Forming Methods: A Comparison of Microstructure and Mechanical Properties

[+] Author and Article Information
S. H. Hosseini

School of Mechanical Engineering,
Iran University of Science and
Technology (IUST),
Tehran 16846-13114, Iran
e-mail: Hadi_Hosseini@mecheng.iust.ac.ir

M. Sedighi

School of Mechanical Engineering,
Iran University of Science and
Technology (IUST),
Tehran 16846-13114, Iran
e-mail: Sedighi@iust.ac.ir

1Corresponding author.

Manuscript received July 15, 2017; final manuscript received June 22, 2018; published online July 27, 2018. Assoc. Editor: Yannis Korkolis.

J. Manuf. Sci. Eng 140(10), 101008 (Jul 27, 2018) (7 pages) Paper No: MANU-17-1438; doi: 10.1115/1.4040724 History: Received July 15, 2017; Revised June 22, 2018

Expanding performance of friction power in material processing techniques, considerably improves the process efficiency while decreases required load and increases imposed strain by the localized material softening. This paper proposes friction-assisted tube forming (FATF) and friction-assisted tube extrusion (FATE) to deform cylindrical tubes for desirable radius and thickness. These methods were successfully examined on commercially pure copper tubes. Finite element (FE) analyses were executed to simulate heat generation, temperature, and strain fields. Using friction power in the presented methods significantly reduced processing force and enhanced imposed strain. Therefore, FATF and FATE show a great capability to forming and extrusion of the cylindrical tubes with minimum processing power. Mechanical properties of the processed tubes showed considerable changes in which yield strength and ultimate tensile strength increased 4.6 and 1.6 times greater than those from the initial values. Dynamically recrystallized fine grains with mean size of 8.3 μm were obtained compared with 60 μm for the annealed sample.

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Fig. 1

Simple schematics of: (a) FATF and (b) FATE

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Fig. 2

Copper tubes processed by FATF (a) and FATE (b)

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Fig. 3

(a) The copper tube marked with rectangular grids and (b) deformation of the copper tube after FATF

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Fig. 4

Nodal temperature distribution in (a) FATF and (b) FATE

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Fig. 5

Comparisons of equivalent plastic strain and deformation behavior in (a) FATF and (b) tube forming, (c) FATE, and (d) tube extrusion

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Fig. 6

Equivalent plastic strain in FATF and TF along thickness

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Fig. 7

Equivalent plastic strain in FATE and TE along thickness

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Fig. 8

Force versus displacement graph of FATF and TF

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Fig. 9

Force versus displacement graph of FATE and TE

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Fig. 10

Comparison of the force displacement graph of FEA and experiment during FATF processes

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Fig. 11

Optical micrograph of the annealed tube (a) processed by FATF (b) and FATE (c) processes

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Fig. 12

Vickers microhardness versus distance of annealed tube and processed by FATF and FATE processes

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Fig. 13

Stress–strain behavior of tubes after annealing, FATE and FATF process



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