Master of Science, The Ohio State University, 2021, Mechanical Engineering
Recent advances in metal tube forming processes, motivated by a heightened interest in mass customization of lightweight tubular metallic structures, have led to significant improvements in their accuracy. Against this backdrop, Incremental Profile Forming (IPF) was invented in 2013 at the Technical University of Dortmund (TUD), Germany, to manufacture tubular structures with high geometric complexity. IPF holds considerable advantages over conventional forming techniques in its capability to meet the demands of process flexibility and product complexity.
In IPF, the desired geometry is generated by a set of tools placed circumferentially around the tube and programmed to execute superposed radial, axial and circumferential motions to change local cross-sectional geometry. To promote tighter product property and geometric control in IPF, the tool motion must be precise, and must also account for material springback upon unloading and non-uniform distribution of plastic strain in the forming region. This requires an understanding of the process mechanics, and integration of that knowledge into the control strategy and implementation. This thesis presents quantitative models, results from limited experiments, and extensive numerical FEM results to enable an improved understanding of the process mechanics in IPF. Particularly, two analytical models are developed to describe radial indentation, which is a component of many IPF processes.
The first model, called the three-circle model, is based on regression analysis and geometric insights from studying the plastic collapse of tubular structures under lateral loads. It draws upon numerical FEM simulations of radial indentation. Making use of moving and stationary plastic hinges to impose or remove curvature at material points on the tube, the model reconstructs the deformed cross-section at any axial location for a given set of problem parameters. The feasibility of the three-circle model is validated by comparing wi (open full item for complete abstract)
Committee: Satyanarayana Seetharaman (Advisor); Krishnaswamy Srinivasan (Advisor); Erman Tekkaya (Committee Member)
Subjects: Mechanical Engineering