Forming Box-Shaped Ends in Circular Tubes

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1 INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 16, No. 9, pp AUGUST 2015 / 1975 DOI: /s ISSN (Print) / ISSN (Online) Forming Box-Shaped Ends in Circular Tubes Chin-Joo Tan 1,2,#, Judha Purbolaksono 1,2, and Wen-Tong Chong 1 1 Department of Mechanical Engineering, Faculty of Engineering, University of Malaya, Kuala Lumpur, Malaysia 2 Centre of Advanced Manufacturing and Material Processing (AMMP Centre), Level 8, Engineering Tower, Faculty of Engineering, University of Malaya, Kuala Lumpur, Malaysia # Corresponding Author / tancj1@yahoo.com, TEL: , FAX: KEYWORDS: Balusters, Tube forming, End forming, Decorative columns, Box shape, Plastic reshaping This study is aimed to form a pair of axially displaced box-shaped ends from a circular tube. In this process, one tube end is first expanded into a circular section having a diameter equal to the diagonal length of the target square using a conical top circular die. A square punch having a conical bottom end and a tapered square die are then used to draw the expanded section into a square box. The side walls of the box are flattened at an ironing ratio of 15% corresponding to its initial wall thickness. The expansion and squaring processes are repeated at the opposite tube end. However, the tapered die in the final stage is oriented at 45 relative to the square punch and tube to form an axially displaced square section at the opposite end. Both the experiments and FE simulations were performed to evaluate this process. A pair of axially displaced box-shaped ends having small corner radii is successfully obtained from the experiment and the simulation. With the developed process, the design of steel balustrades is improved and similar to the precast or stone balustrades. Manuscript received: March 23, 2014 / Revised: February 12, 2015 / Accepted: May 28, 2015 NOMENCLATURE s 1 = Punch stroke in 1st stage s 3 = Punch stroke in 3rd stage 1. Introduction Balusters are normally made of plasters, stones, woods and wrought irons. It is usually formed by a molding, carving or forging process. Although there are some steel balusters in the market, its designs are very simple i.e. either in straight round or square. Despite its stylish surface, the aesthetic quality of the stainless steel tube is not as good as the carved or the molded ones due to its simple shape. Hence, it is important to reshape the steel tube to improve its aesthetic value. Plastic reshaping of round tubes into different cross sections have been mainly performed by cold rolling, hydroforming and tube end forming process. In the cold rolling process, the round tubes are continuously passed through a series of flat idle rollers at reducing roll gap in each pass until the circular sections are completely reshaped into square sections. Kiuchi et al. 1-4 theoretically analyzed and optimized the reshaping process. Kiuchi and Feizhou 5 developed a simulation program based on 3D elastoplastic finite element method for the reshaping of round pipes into square and rectangular pipes. Naeini et al. 6 have designed roll profiles and pass-schedules for the reshaping of round tube into the pentagonal cross-section. Bayoumi 7 analytically solved the problem for the cold flattening of a round tube into an oblong shape by means of rolling process. Abrinia and Farahmand 8 solved the reshaping of a thick square tube from a round one based on the upper bound method. Bayoumi and Attia 9 presented an analytical solution and finite element simulation using the ABAQUS/ STANDARD and LS-DYNA to reshape a round tube into a square section through four flat rolls. However, reshaping by rolling produces only the continuous profile along the tube. It cannot form a tube having multiple cross sectional shapes. Hydroforming of a round tube inside a box-shaped die had been widely presented by others. Chen et al. 10 modeled hydroforming of a round tube inside a square die cavity with and without end feeding. Hwang and Altan 11 analyzed the plastic flow pattern for the expansion or crushing process of a round tube into a rectangular cross-section. The ratio of the corner radius of the square section to its initial wall thickness was 2.4. Kridli et al. 12 discussed the effect of strain hardening component and die corner radii on thickness distribution of hydroformed parts. Orban and Hu 13 developed an analytical model to determine the variation in the stresses and strains along the tube wall as the internal pressure increases to expand the circular tube into a KSPE and Springer 2015

2 1976 / AUGUST 2015 INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 16, No. 9 square cross-section. Loh-Mousavi et al. 14 improved the die corners filling in a box-shaped tube hydroforming by control of wrinkling. In hydroforming process, an effective sealing system between the tube ends and the inlet of the pressurized water is required to sustain the high internal pressure inside the tube during expansion. In addition, a certain length of tube end is required for axial feeding and for clamping during forming. Therefore, hydroforming of the tube ends into box shape is not feasible. In the tube end forming process, Fernandes et al. 15 developed a forming process for producing a hexahedral heads with washers in tubular screws by means of a combined finite element-boundary element approach. Alves et al. 16 directly pierced the round tube end with a square punch. A square section having large corner radii was formed. The authors 17 improved the square look of the section by compressing the expanded conical end of the tube into a square section. A similar method of compression was used to reduce the corner radius of a rectangular cup 18 and to locally thicken the inner corner of a steel wheel disk. 19 In this study, a 4-stage forming process was developed to form a pair of box-shaped ends from a seamless API tube by axial compression. The tube end was expanded in the 1st stage and then formed into a box shape in the next stage. The bottom end was uneven and it was trimmed off later. The expansion and compression processes were repeated at the opposite tube end in the 3rd and 4th stages. In addition, a pair of axially displaced square sections was formed by changing the orientation of the tools in the 4th stage. Fig. 1 Developed 4-stage forming process for a steel baluster 2. Conditions for FE Simulation The developed forming process for a steel baluster is illustrated in Fig. 1. In the 1st stage, a round tube was placed on top of the conical top circular die. The tube was axially compressed by a flat punch to a diameter equal to the diagonal length of the target square section for a punch stroke, s 1 = 50 mm. In the 2nd stage, the central axis of a conical bottom square punch was aligned with the central axis of the tube before pushing it through the tapered square ironing die to form the square section. The square section was then separated from the punch. The similar tube expansion and squaring processes were repeated at another tube end in the 3rd and 4th stages using the same set of tools. A steel baluster having box shapes at its both ends were finally formed. ABAQUS / Standard Ver using implicit integration scheme was employed in the simulation to evaluate the feasibility of the developed process prior to experiment. Failures such as localized necking and buckling can be predicted with the Finite Element (FE) simulation. The combined ¼ FE model for the developed forming process is illustrated in Fig. 2. Only ¼ of the model was constructed to reduce the calculation time. The model was assumed to be symmetrical at both the 1-3 and 2-3 planes. The Coulomb friction was assumed at the interfaces between the tools and the blank. The friction coefficients at all interfaces were set at 0.1. The required CPU time for the 4-stage forming process was 12 Hours 52 Minutes 17 Seconds. Only the tube was modeled as deformable and all tools were treated as discrete rigid. The deformable material was treated as homogenous and isotropic. The Fig. 2 Combined ¼ FE model for developed 4-stage forming process average size of the deformable elements was 1.6 mm 0.7 mm 1.6 mm. The number of deformable elements was and the number of discrete rigid nodes was The tube was divided into eight-node linear brick elements with hourglass control and reduced integration. Fig. 3 shows the flow stress curve of the tube. It was obtained from a uni-axial tensile test and used to define the plastic property of the deformable material in the FE simulation. The elastic modulus and Possion s ratio of the material are set at 206 GPa and 0.3, respectively. The deformations were divided into multi-step as illustrated in Fig. 1. A duplicate set of tools were placed at the opposite tube end to form another similar square section. All tools were only active at its associated step and would be inactive after that.

3 INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 16, No. 9 AUGUST 2015 / 1977 Fig. 3 Flow stress curve of the tube used in FE simulation Fig. 5 Detailed dimensions of tools induction hardened to improve its galling resistance against friction during ironing. The conical angles for the conical top circular die and the conical bottom square punch were set at the same angle of 30 to facilitate the drawing of the expanded circular section into the square die. The tapered angles of the square die were fixed at 10 and 25 respectively for the reduction in forming load. The clearance between the square punch and die was 3.0 mm corresponding to 85.7% of the initial wall thickness of the tube for flattening purpose. 4. Experimental and Simulated Results Fig. 4 Experimental setup for 4-stage forming process 3. Experimental Procedures 3.1 Four-stage forming of aligned box-shaped ends The experimental setup for the 4-stage forming process is shown in Fig. 4. In the 1st stage, an API seamless tube measuring 130 mm in length with an outer diameter of 48 mm and an initial wall thickness of 3.5 mm was placed on top of the conical top circular die. A conical bottom square punch was used to push the expanded section of the tube into a tapered square die to form the square box in the 2nd stage. In the 3rd stage, the tube was pressed over the same circular die at its opposite tube end. An inverted tapered square die was placed in the middle of the tube before the compression to facilitate the squaring process in the 4th stage. After the 3rd stage, the tapered square die was inverted together with the tube and placed on top of the die holder. A square punch was then used to push the expanded section of the tube into the tapered square die. A 600 kn Universal Testing Machine was employed in the test. The testing speed was set at 10 mm/min. All contact surfaces were lubricated with the commercial high viscosity neat oil. 3.2 Detailed dimensions of tools Only three tools were used in the experiment to evaluate the developed process. The detailed dimensions of the tools are shown in Fig. 5. All tool surfaces except the conical top circular die were 4.1 Deformation behaviors and plastic-strain distributions Although only the ¼ model was considered in the simulation, the calculated results were mirrored along the 1-3 and 2-3 planes for display in a full model. The finite element predicted distribution of effective strain at the end of the 1st, 2nd, 3rd and 4th stages of the proposed forming process are illustrated in Fig. 6. In the 1st stage, the plastic strain increased linearly towards the tube end when the diameter of the circular section became large. The wall thickness around the bottom end was small due to expansion. In the 2nd stage, the plastic strain around the corner was high due to the compression of the circular end into square corner radii. The distribution of plastic strains was uniform along the side walls due to ironing. Since the wall thickness around the circular bottom end was small, the amount of ironing in this area became less. Hence, a small plastic strain was obtained around the bottom end. In the 3rd stage, the uneven bottom end of the square box was vertically pressed for the expansion of the opposite tube end. Due to the flattening of the uneven bottom end under the compression, the plastic strains were increased around the square corners. In the 4th stage, the circular section was compressed into a square section. Hence, high plastics strains were observed around the corners. No failure was observed in the deformed tubes and there was no buckling in the middle circular sections. The finite element predicted distribution of effective strain for different displacements of the punch in the 2nd stage are illustrated in Fig. 7. The highest plastic strains were observed around the corners due to the compression. The materials tend to flow to the corners under

4 1978 / AUGUST 2015 INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 16, No. 9 Fig. 6 Finite element predicted distribution of effective strain at the end of the 1st, 2nd, 3rd and 4th stages of the proposed forming process Fig. 8 Comparison of product dimensions between simulation and experiment Fig. 7 Finite element predicted distribution of effective strain for different displacements of the punch in the 2nd stage compression resulting in small corner radii and uneven bottom end. 4.2 Dimensions of the formed product The comparison of the product dimensions between the simulation and the experiment is shown in Fig. 8. The actual side lengths of the square section i.e mm were almost equal to the target side lengths of 51.0 mm. The ratio of the outer corner radius to the side wall thickness was 0.88, about one third of that for hydro-formed parts i.e. 2.4 as reported by Hwang and Altan. 11 The thickness distribution of the cross section is more even than the hydro-formed part. No reduction in thickness is observed around the square corners, whereas around 11-25% of reduction in thickness for hydro-formed parts had been reported. 11,12 The part accuracy of the box shape i.e. the square look improves when the corner radii is reduced. The developed process has improved the part accuracy in comparison to the hydroforming process. The equipment cost is also reduced as no hydraulic pump is required in the developed process. The side wall thickness obtained from the simulation was slightly larger than the experimental one due the elastic deformation of the tapered square die during the squaring process in the 2nd and the 4th stage. Hence, fewer materials were pushed toward the bottom end leading to a smaller height of the square section than the simulated one. Due to the flatness accuracy of the initial round tube ends and the difficulty in aligning the tube central axis with the punch and die central axes in the experiment, the square section has an unbalanced wall thickness distribution at each side wall with different heights. Trimming of the uneven bottom end leads to the formation of the short section. Since all tools were assumed as rigid and the Fig. 9 Forming loads obtained from experiment and simulation for 4- stage forming process and s = 50 mm alignment between the tube and the punches was perfect in the simulation, the side walls thickness of the square section was balanced and close to the target value of 3.0 mm with a height of 17.5 mm larger than the experimental one of 15.5 mm. 4.3 Forming loads in 4-stage forming process Forming loads obtained from the experiment and the simulation for the developed 4-stage forming process and s = 50 mm are shown in Fig. 9. The forming loads in the 1st and 3rd stages increased almost linearly with the punch strokes. The amount of increase in forming load reduced after the tube end passed through the die shoulder as the tube end stopped expanding but started curling at its side wall. The maximum load was reduced by about 25% compared to the projected expansion load using a full conical die for the same punch stroke. Hence, buckling in the middle circular section of the tube was prevented with the conical top circular die. The forming loads at one tube end were almost identical to the ones obtained from another tube

5 INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 16, No. 9 AUGUST 2015 / 1979 Fig. 10 Orientation of tools and tube to form 45 axially displaced square sections in 4th stage Fig. 11 Experimental setup in 4th stage end for the same amount of punch stroke (i.e. s = 50 mm in the 1st and 3rd stages) as there were no deformations occurred in the circular section. The calculated results agree well with the experimental ones. The saw tooth oscillations in the evolution of the forming load with displacement are due to progressive contact or release of individual nodes with the surfaces of the tools. Since the maximum forming load is lower than the buckling limit of the tube, it is possible to heighten the section by increasing the punch travel in the 1st and 3rd stages. Although the forming loads in the 1st and 3rd stages are coincident, the ones in the 2nd and 4th stages are slightly different from each other. In tube end forming process, it is difficult to obtain a consistent and accurate vertical alignment of the tube during compression as there is no constraint along the tube side wall. The vertical alignment of the tube is only dependent on the degree of flatness of the contacting surfaces at its both ends. Forming loads might vary due to the change in vertical alignment during the compression. Since both tube ends were trimmed perpendicularly to its central axis before the 1st and 3rd stages and the tube ends are in firm contact with the flat punch and conical top of the circular die. Therefore, the contacting surfaces were flat and the vertical alignment is good. However, the vertical alignments of the tube are not consistent in the 2nd and 4th stages as there were only point-to-surface contacts between the circular expanded section and the tapered square die. Therefore, the forming loads in the 2nd and 4th stages are slightly different from each other. 5. Formation of 45 o Axially Displaced Box-Shaped Ends Fig. 12 Distribution of plastic strains and the finite element model of tube having axially displaced square sections at both ends Fig. 13 Comparison between steel balusters having aligned square sections and one having axially displaced square sections obtained from the experiment The orientation of the tools and the tube for the formation of the 45axially displaced square sections in the 4th stage is illustrated in Fig. 10. In this stage, the vertical edges of the opposite square box were positioned at 45 relative to the vertical edges of the square punch. The square punch pushed the expanded section through the tapered square die to form the axially displaced square section at another tube end. The experimental setup in the 4th stage is shown in Fig. 11. The distribution of plastic strains and the finite element model of the tube having axially displaced square sections at its both ends are shown in Fig. 12. The highest value of strains was observed around the corners of the 2nd square section and its distribution is almost identical to the 1st one as shown in Fig. 6. A pair of square boxes having an axially displaced angle of 45 was successfully formed at both ends of the round tube. The comparison between the steel balusters having aligned square sections and the one having axially displaced square sections obtained from experiment is shown in Fig. 13. The design of the baluster was improved with an axially displaced square section. The chrome-plated steel balusters are more stylish than the conventional molded and carved balusters. Forming loads obtained from the experiment and the simulation for the axially displaced square sections is shown in Fig. 14. The calculated results agree well with the experimental ones. Since the same set of tools was used in the formation of both the aligned sections and axially

6 1980 / AUGUST 2015 INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 16, No Kiuchi, M., Naeni, H. M., and Shintani, K., A Numerical Simulation for the Reshaping Processes of Non-Circular Pipes, Proc. of the 9th International Conference on Sheet Metal, pp , Kiuchi, M. and Feizhou, W., Reshaping of Round Pipes into Square and Rectangular Pipes, Journal of Tube and Pipe Technology, pp , Fig. 14 Forming loads obtained from experiment and simulation for axially displaced square sections displaced sections, the distribution of forming loads was almost the same in these two processes. 6. Conclusions A 4-stage forming process of a steel baluster having a box shape at its both ends was developed. Square sections having side lengths of 51.1 mm and an average height of about 15.5 mm were successfully formed at the both ends of a round tube in the experiment. The design of the baluster was further improved by the formation of an axially displaced square section at its opposite end. The aesthetic value of the steel balusters was increased with the developed process using only 3 simple tools. In comparison to the hydroforming process, the developed process has improved the accuracy of the box shape and reduced the cost of equipment as no hydraulic pump is required in this process. ACKNOWLEDGEMENTS The authors would like to thank University of Malaya for providing the research grant support under the project no. RP021A-13AET and UM.C/HIR/MOHE/ENG/53. REFERENCES 1. Kiuchi, M., Naeni, H. M., and Shintani, K., Numerical Analysis of Reshaping Processes of Pipes with Non-Circular Cross Section, Advanced Technology, Vol. 3, pp , Kiuchi, M., Naeini, H. M., and Shintani, K., Computer Aided Design of Rolls for Reshaping Processes from Round Pipes to Channel-Type Pipes, Journal of Materials Processing Technology, Vol. 111, No. 1, pp , Kiuchi, M., Naeni, H. M., and Shintani, K., Automated Design System of Rolls for Reshaping Processes of Pipes with Non-Circular Cross Section, Proc. of the 4th International Conference of Iranian Society of Mechanical Engineering, pp , Naeini, H. M., Kiuchi, M., Kitawaki, T., and Kuromatsu, R., Design Method of Rolls for Reshaping Processes of Pipes with Pentagonal Cross-Sections, Journal of Materials Processing Technology, Vol. 169, No. 1, pp. 5-8, Bayoumi, L. S., Analysis of Flow and Stresses in Flattening a Circular Tube by Rolling, Journal of Materials Processing Technology, Vol. 128, No. 1, pp , Abrinia, K. and Farahmand, H. R., An Upper Bound Analysis for the Reshaping of Thick Tubes with Experimental Verification, International Journal of Mechanical Sciences, Vol. 50, No. 2, pp , Bayoumi, L. S. and Attia, A. S., Determination of the Forming Tool Load in Plastic Shaping of a Round Tube into a Square Tubular Section, Journal of Materials Processing Technology, Vol. 209, No. 4, pp , Chen, J. Y., Xia, Z. C., and Tang, S. C., Corner Fill Modeling of Tube Hydroforming, Proc. of the ASME, Vol. 11, pp , Hwang, Y.-M. and Altan, T., Finite Element Analysis of Tube Hydroforming Processes in a Rectangular Die, Finite Elements in Analysis and Design, Vol. 39, No. 11, pp , Kridli, G. T., Bao, L., Mallick, P. K., and Tian, Y., Investigation of Thickness Variation and Corner Filling in Tube Hydroforming, Journal of Materials Processing Technology, Vol. 133, No. 3, pp , Orban, H. and Hu, S. J., Analytical Modeling of Wall Thinning during Corner Filling in Structural Tube Hydroforming, Journal of Materials Processing Technology, Vol. 194, No. 1, pp. 7-14, Loh-Mousavi, M., Mori, K., Hayashi, K., and Bakhshi, M., Improvement of Filling of Die Corners in Box-Shaped Tube Hydroforming by Control of Wrinkling, Key Engineering Materials, Vol. 334, pp , Fernandes, J. L. M., Alves, L. M., and Martins, P. A. F., Forming Tubular Hexahedral Screws-Process Development by Means of a Combined Finite Element-Boundary Element Approach, Engineering Analysis with Boundary Elements, Vol. 36, No. 7, pp , Alves, M. L., Almeida, B. P. P., Rosa, P. A. R., and Martins, P. A. F., End Forming of Thin-Walled Tubes, Journal of Materials Processing Technology, Vol. 177, No. 1, pp , 2006.

7 INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 16, No. 9 AUGUST 2015 / Tan, C. J., Chong, W. T., and Hassan, M. A., End Formation of a Round Tube into a Square Section Having Small Corner Radii, Journal of Materials Processing Technology, Vol. 213, No. 9, pp , Mori, K., Nishijima, S., and Tan, C. J., Two-Stage Cold Stamping of Magnesium Alloy Cups Having Small Corner Radius, International Journal of Machine Tools and Manufacture, Vol. 49, No. 10, pp , Tan, C. J., Abe, Y., Mori, K., Ebihara, O., and Nonaka, T., Increase of Wall Thickness Around Corner of Multi-Stage Drawn Cup with Flange using Conical Punches, Key Engineering Materials, Vols , pp , 2007.

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