Design and development of a flow forming machine

Flow forming is an advanced version of metal spinning process which is used to manufacture sheet metal products having symmetrically axial geometry and also to produce long thin-wall tubes with precision dimensions and desired mechanical property. In flow forming of tubes, the workpiece is held onto...

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Main Author:	Mustapa, Mohd. Shamsulizan
Format:	Thesis
Language:	English
Published:	2015
Subjects:	TJ Mechanical engineering and machinery
Online Access:	http://eprints.utm.my/id/eprint/48686/1/MohdShamsulizanMustapaMFKM2015.pdf
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id	my-utm-ep.48686
record_format	uketd_dc
spelling	my-utm-ep.486862020-06-17T02:49:21Z Design and development of a flow forming machine 2015 Mustapa, Mohd. Shamsulizan TJ Mechanical engineering and machinery Flow forming is an advanced version of metal spinning process which is used to manufacture sheet metal products having symmetrically axial geometry and also to produce long thin-wall tubes with precision dimensions and desired mechanical property. In flow forming of tubes, the workpiece is held onto the mandrel as the forming roller moves along the workpiece axially to reduce the diameter. Author has developed a few concepts of flow forming tool that built to accommodate the lathe tool post. One of the concept consists of two rollers set has been fabricated. This tool is rigid enough to perform flow forming at lathe machine and can flow-form tubes with a diameter up to 100mm. This tooling assembly is attached at Pinacho SP/165 conventional lathe machine to perform flow forming process. The selected work material is aluminium alloy 6061 that widely applied at light-weighted industries. The main objectives of this research is to analyse the influences of major process parameters such as feed rate, spindle speed and depth of cut on wall thickness changes, internal diameter growth and roundness of the finished products. The dimensions of the finish products are measured using Carl Zeiss Coordinate Measuring Machine. It is found that wall thickness changes decreases and external diameter increases as the roller travels along the tube. It is also found that higher feed rate of rollers and lower thickness reductions have advantages for obtaining smaller internal diameter growth. The tube with good roundness also can be obtained by flow-form the tube using lower thickness reductions. Material structure test also has been conducted to confirm the direction of the flow of material during the process. 2015 Thesis http://eprints.utm.my/id/eprint/48686/ http://eprints.utm.my/id/eprint/48686/1/MohdShamsulizanMustapaMFKM2015.pdf application/pdf en public http://dms.library.utm.my:8080/vital/access/manager/Repository/vital:83782?queryType=vitalDismax&query=Design+and+development+of+a+flow+forming+machine&public=true masters Universiti Teknologi Malaysia, Faculty of Mechanical Engineering Faculty of Mechanical Engineering
institution	Universiti Teknologi Malaysia
collection	UTM Institutional Repository
language	English
topic	TJ Mechanical engineering and machinery
spellingShingle	TJ Mechanical engineering and machinery Mustapa, Mohd. Shamsulizan Design and development of a flow forming machine
description	Flow forming is an advanced version of metal spinning process which is used to manufacture sheet metal products having symmetrically axial geometry and also to produce long thin-wall tubes with precision dimensions and desired mechanical property. In flow forming of tubes, the workpiece is held onto the mandrel as the forming roller moves along the workpiece axially to reduce the diameter. Author has developed a few concepts of flow forming tool that built to accommodate the lathe tool post. One of the concept consists of two rollers set has been fabricated. This tool is rigid enough to perform flow forming at lathe machine and can flow-form tubes with a diameter up to 100mm. This tooling assembly is attached at Pinacho SP/165 conventional lathe machine to perform flow forming process. The selected work material is aluminium alloy 6061 that widely applied at light-weighted industries. The main objectives of this research is to analyse the influences of major process parameters such as feed rate, spindle speed and depth of cut on wall thickness changes, internal diameter growth and roundness of the finished products. The dimensions of the finish products are measured using Carl Zeiss Coordinate Measuring Machine. It is found that wall thickness changes decreases and external diameter increases as the roller travels along the tube. It is also found that higher feed rate of rollers and lower thickness reductions have advantages for obtaining smaller internal diameter growth. The tube with good roundness also can be obtained by flow-form the tube using lower thickness reductions. Material structure test also has been conducted to confirm the direction of the flow of material during the process.
format	Thesis
qualification_level	Master's degree
author	Mustapa, Mohd. Shamsulizan
author_facet	Mustapa, Mohd. Shamsulizan
author_sort	Mustapa, Mohd. Shamsulizan
title	Design and development of a flow forming machine
title_short	Design and development of a flow forming machine
title_full	Design and development of a flow forming machine
title_fullStr	Design and development of a flow forming machine
title_full_unstemmed	Design and development of a flow forming machine
title_sort	design and development of a flow forming machine
granting_institution	Universiti Teknologi Malaysia, Faculty of Mechanical Engineering
granting_department	Faculty of Mechanical Engineering
publishDate	2015
url	http://eprints.utm.my/id/eprint/48686/1/MohdShamsulizanMustapaMFKM2015.pdf
_version_	1747817451014324224

Design and development of a flow forming machine

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