Research Papers

High Strain, High Strain Rate Forming of Difficult to Deform Tubular Parts

[+] Author and Article Information
K. Kluz, E. S. Geskin

Department of Mechanical and Industrial Engineering, New Jersey Institute of Technology, University Heights, Newark, NJ 07102-1982

J. Manuf. Sci. Eng 131(6), 061009 (Dec 03, 2009) (8 pages) doi:10.1115/1.4000561 History: Received March 27, 2009; Revised October 24, 2009; Published December 03, 2009; Online December 03, 2009

High demand for formed tubular components and the necessity to increase their strength to weight ratio have established a need for new, effective, and low cost forming technologies. This work investigates the application of a propellant-driven water stream to the formation of high tensile strength alloys such as stainless steel 321, Inconel 625, and Ti–3Al–2.5V. The proposed forming technology is based on the utilization of high pressure developed in liquid flowing through a tubular work piece. This pressure results from superposition of compression waves generated in the course of the impact of the liquid by products of propellant combustion. An experimental setup, used for the study of the technology in question, consisted of a tubular component, inserted into a split die assembly, and a combustion chamber, which generated gas, driving water through a work piece. This setup was successfully used for high strain, high strain rate forming of tubular components. In particular, the formation of various shapes in the course of an expansion of seamless tubing was examined. Despite large strains, exceeding in some cases the static test elongation limit, the generated samples were characterized by a uniform wall thinning and structural integrity. For example, a 55% expansion of Ti–3Al–2.5V tube was attained using a simple setup. The acquired experimental data show that the technology can be applied to form alloys characterized by high tensile strength, low static elongation limits, and low modulus of elasticity. Simplicity and low capital cost of the process determine its competitiveness in comparison to conventional quasistatic hydroexpansion, hot forming, and high-energy rate explosive forming processes.

Copyright © 2009 by American Society of Mechanical Engineers
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Figure 2

Dynamic response of barrel near shell chamber versus calculated propellant gas pressure

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Figure 3

Strain gauge reading versus CFD sampled pressure with indicated periods of oscillation

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Figure 1

Schematic of propellant-driven water projectile launcher

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Figure 4

Nonelastic deformation of internal barrel bore; radiographic investigation with actual diameter measurement

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Figure 5

Schematic of device for deformation of tubular parts

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Figure 6

Variation in water pressure at different cross sections of barrel (computational results): dimensions in (mm)

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Figure 7

AMS 5557, one-side expanded sample

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Figure 8

AMS 5557, one-sided deformation; dimensional analysis of deformed shape

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Figure 9

AMS 4943, one-sided deformation; dimensional analysis of deformed shape

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Figure 10

AMS 5581, two-side expanded sample

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Figure 11

AMS 5581, two-sided deformation; dimensional analysis of generated shape

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Figure 12

AMS 4943, two-sided deformation; dimensional analysis of deformed shape

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Figure 13

AMS 4943, two-sided deformation—metallographic sample

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Figure 14

55% symmetric expansion of AMS 4943 titanium alloy tube; original wall thickness is 0.0355 in. (0.90 mm)

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Figure 15

AMS 4943 aerospace part, multiple elliptical cross sections formed from round tube



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