New technique of precision necking for long tubes with variable wall thickness

doi:10.1007/s11465-019-0565-7

Front. Mech. Eng.

2020, Vol. 15

Issue (4) : 622-630 https://doi.org/10.1007/s11465-019-0565-7

RESEARCH ARTICLE

New technique of precision necking for long tubes with variable wall thickness

Yongqiang GUO¹(

), Chunguo XU¹, Jingtao HAN², Zhengyu WANG¹

¹. Beijing Research Institute of Mechanical and Electrical Technology, Beijing 100083, China
². School of Materials Science and Engineering, University of Science and Technology Beijing, Beijing 100083, China

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Abstract

This study analyzed the deformation law of rear axles with variable wall thickness under bidirectional horizontal extrusion and found that necking was accompanied by upsetting deformation through theoretical calculation, numerical simulation, and experimental research. The sequence and occurrence of necking and upsetting deformations were obtained. A theory of deformation was proposed by controlling the distribution of temperature field. Effective processes to control the wall thickness of rear axle at different positions were also proposed. The ultimate limit deformation with a necking coefficient of 0.68 could be achieved using the temperature gradient coefficient. A new technology of two-step heating and two-step extrusion for a 13 t rear axle was developed, qualified test samples were obtained, and suggestions for further industrial application were put forward.

Keywords extrusion rear axle necking coefficient temperature gradient

Corresponding Author(s): Yongqiang GUO

Just Accepted Date: 15 November 2019 Online First Date: 17 December 2019 Issue Date: 02 December 2020

Cite this article:

Yongqiang GUO,Chunguo XU,Jingtao HAN, et al. New technique of precision necking for long tubes with variable wall thickness[J]. Front. Mech. Eng., 2020, 15(4): 622-630.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-019-0565-7
https://academic.hep.com.cn/fme/EN/Y2020/V15/I4/622

Fig.1 Diagram of a rear axle (unit: mm).

Fig.2 Model of necking.

Fig.3 Schematic of necking deformation.

Temperature/°C	$σ s$ /MPa
25	660
200	602
400	526
600	350
800	146
1000	82
1200	43

Tab.1 Values of

σ s

under different temperatures

Fig.4 P, P_cr, and P_u curves at room temperature.

Fig.5 Comparison of numerically simulated and experimental wall thickness.

Fig.6 Forming process of tube in local heating conditions. (a) End heated as a whole; (b) end heated with temperature gradient.

Fig.7 Finite element model of the necking process.

Fig.8 Formed length of the 108 mm tube with different temperature gradient coefficients.

Fig.9 effective stress diagram with different temperature gradient coefficients of the 178 mm tube.

Fig.10 Experimental production line of the new forming technology.

Fig.11 Distribution of temperature field of test sample. (a) Temperature gradient before necking; (b) temperature gradient after necking.

Fig.12 Actual temperature measurements at the end of the tube.

Fig.13 Instability phenomenon. (a) Instability in the transmission area; (b) instability in the necking area.

Fig.14 Temperature distribution of (a) the first process and (b) the second process.

Fig.15 Actual procedure. (a) First heating; (b) first necking; (c) second heating; (d) second necking.

Fig.16 Shape and inner cavity of qualified products. (a) External shape; (b) internal wall thickness.

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