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Material Flow in Infeed Rotary Swaging of Tubes.

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Lubrication significantly impacts rotary swaging, a metal forming process. Optimal lubricant conditions maximize workpiece elongation, enabling better control over final product geometry and mechanical properties.

Keywords:
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Area of Science:

  • Materials Science and Engineering
  • Manufacturing Processes
  • Tribology

Background:

  • Rotary swaging is an incremental metal forming process used to reduce part cross-sections, notably affecting wall thickness in tubular components.
  • Material flow during swaging is complex, influencing final geometry, mechanical properties, and local cold hardening.
  • Lubrication is a critical factor affecting geometry changes and material flow during rotary swaging.

Purpose of the Study:

  • To investigate the dependency of material flow on lubrication conditions in rotary swaging.
  • To understand how to control material flow for desired properties in swaged parts.
  • To verify simulation results with experimental data on tube wall thickness changes.

Main Methods:

  • Utilized simulations with combined hardening material models.
  • Verified simulation outcomes by analyzing the change in wall thickness of tubes.
  • Conducted experiments to validate simulation findings on material flow and workpiece elongation.

Main Results:

  • Friction conditions significantly influence workpiece back-shifting and stroke-induced elongation.
  • Specific lubricant conditions were identified as leading to the highest axial elongation of the workpiece.
  • Simulation and experimental results demonstrated a clear correlation between lubrication and material flow.

Conclusions:

  • Lubrication conditions are a key determinant of material flow and axial elongation in rotary swaging.
  • Optimizing lubrication can enable precise control over the geometry and mechanical properties of swaged parts.
  • This research provides insights for controlling rotary swaging processes to achieve desired product characteristics.