An axial wrinkle defect was observed in the inner wall of the sinking zone of a thick-wall steel tube processed by cold radial forging. Wrinkles can evolve into fissures. The present study focuses on the evolution of wrinkles and the effects of process parameters on them using a three-dimensional radial forging process finite element model, radial forging experiments, and surface morphology observations. The results indicated that the vertical section angle of the hammer die and the size of the tube blank significantly affect the evolution of wrinkles. The height-towidth ratio λ was introduced to describe the morphology of wrinkles. It had an approximately linear relationship with the radius reduction in the sinking zone. There was a linear correlation between the growth slope of λ and the axial to circumferential strain ratio|εr/εθ|, which can predict the λ under few process parameters. For the 30SiMn2MoVA steel, at the junction of the forging and sinking zones, the threshold of λ of the wrinkle that can evolve into a fissure is approximately 1.123.
The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-023-00462-0
Yu-Zhao Yang
,
Cheng Xu
,
Li-Xia Fan
. Evolution of inner wall wrinkle defects in the sinking zone of a thick-walled steel tube during radial forging[J]. Advances in Manufacturing, 2024
, 12(2)
: 396
-408
.
DOI: 10.1007/s40436-023-00462-0
1. Altan T, Boulger FW, Becker JR (1973) Forging equipment, materials and practices. Air Force Materials Laboratory, Ohio
2. Lahoti GD, Altan T (1976) Analysis of the radial forging process for manufacturing rods and tubes. ASME J Eng Ind 98:265–270
3. Domblesky J (1994) Numerical and experimental modeling of multiple pass radial forging of alloy 718. Dissertation, The Ohio State University, US
4. Abedian A, Poursina M, Golestanian HA (2007) Comparison between the properties of solid cylinders and tube products in multi-pass hot radial forging using finite element method. AIP Conf Proc 908:963–968
5. Harrer O, Wallner S, Wieser V et al (2006) Radial forging of a nickel base alloy at different temperature. Steel Grips 4:356–360
6. Chen J, Chandrashekhara K, Richards VL et al (2010) Threedimensional nonlinear finite element analysis of hot radial forging process for large diameter tubes. Mater Manuf Process 25:669–678
7. Fan L, Wang Z, Wang H (2014) 3D finite element modeling and analysis of radial forging processes. J Manuf Process 16:329–334
8. Panov D, Pertsev A, Smirnov A (2019) Metastable austenitic steel structure and mechanical properties evolution in the process of cold radial forging. Materials 12:2058. https://doi.org/10.3390/ma12132058
9. Yang Y, Fan L, Xu C et al (2021) Experimental study of mechanical properties of 30SiMn2MoVA steel gun barrel processed by cold radial forging. J Press Vess Technol ASME 143:011501. https://doi.org/10.1115/1.4047654
10. Xu W, Yang J, Ji P et al (2022) Effect of thickness reduction on residual stress and microstructure inhomogeneity of radial forged Ni-Cr-Mo high strength steel tube. J Mater Eng Perfor. https://doi.org/10.1007/s11665-021-06575-6
11. Li Y, Huang J, Huang G (2014) Comparison of radial forging between the two- and three-split dies of a thin-walled copper tube during tube sinking. Mater Des 56:822–832
12. Chen J (2013) Study on rotary swaging process of micro thinwalled copper tube and quality analysis. Dissertation, South China University of Technology, China
13. Hao Q, Han J, Song J (2014) Causes and remedies for some physical defects in rotary swaged products. Adv Mater Res 941/944:1797–1801
14. Abe H, Furugen M (2010) Method of evaluating workability in cold pilgering of zirconium alloy tube. Mater Trans 51(7):1200–1205
15. Yang Y, Zhang X, Fan L et al (2020) Mechanical properties of steel gun barrel processed by cold radial forging with stepped mandrel under different forging ratios. J Phys Conf Ser 1507:042004. https://doi.org/10.1088/1742-6596/1507/4/042004
16. Tong W, Yang C, Yang Y et al (2020) The experimental study and prediction of wrinkles in sinking zone of barrel forged with chamber and rifled bore. Acta Armamentarii 41:865–873
