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© 2012 Su-Jin Kim GNU Bulk Deforming Manufacturing Processes Tube (Pipe) Bending Straight tube is bended into the desired form. Be careful to buckle inward during bending. Former Clamp Tube bending
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© 2012 Su-Jin Kim GNU© 2012 Su-Jin Kim GNU
Bulk DeformingBulk DeformingManufacturing ProcessesManufacturing Processes
Spring forming machine• Spring forming machine controlled by mechanical cam and link.
http://ma.gnu.ac.kr/vod/Forming/Spring_Former.wmv Spring former
© 2012 Su-Jin Kim GNU© 2012 Su-Jin Kim GNU
Bulk DeformingBulk DeformingManufacturing ProcessesManufacturing Processes
Rotary Swaging
• Split dies separate and close to reduce the diameter and produce a taper of tube.
Tube
Die
Mandrel
© 2012 Su-Jin Kim GNU© 2012 Su-Jin Kim GNU
Bulk DeformingBulk DeformingManufacturing ProcessesManufacturing Processes
Tube (Pipe) Bending• Straight tube is bended into the desired form.• Be careful to buckle inward during bending.
http://ma.gnu.ac.kr/vod/forming/Pipe_Bending.wmv
Form
er
Clamp
Tube bending
© 2012 Su-Jin Kim GNU© 2012 Su-Jin Kim GNU
Bulk DeformingBulk DeformingManufacturing ProcessesManufacturing Processes
Tube Hydroforming
SME: http://www.youtube.com/watch?v=nylIvins3XECom: http://www.youtube.com/watch?v=i2ac6A3FJ6E&hl=ko
• Hydraulic pump injects high pressure fluid inside a hollow tube to expand until it matches a negative mold.
• Strong and light structures for vehicles
Dies
Seals
Hydraulicpressure Tube
© 2012 Su-Jin Kim GNU© 2012 Su-Jin Kim GNU
Bulk DeformingBulk DeformingManufacturing ProcessesManufacturing Processes
Characteristics ( 특징 )
Advantages Disadvantages
Fast & mass production Expensive equipment and dies
Improved strength Ductile materials
Surface finish and tolerance are better than casting
Shape is limited by strain/flowSize is limited by force/equipment
Strength is improved because of work hardening, grain refining, fevering, defect closureSurface finish and tolerance are better than casting, worse than machining
© 2012 Su-Jin Kim GNU© 2012 Su-Jin Kim GNU
Bulk DeformingBulk DeformingManufacturing ProcessesManufacturing Processes
Economics ( 경제성 )• Tool and die cost middle or high but spread over the
number of parts• For large quantities forging is more economical than sand
casting
100 101 102 103 104 105 106
Number of pieces
Cos
t per
pie
ces
1 2
3
4
5
6 7
8
9
Sandcasting
Investment casting
Die casting
Forging
© 2012 Su-Jin Kim GNU© 2012 Su-Jin Kim GNU
Bulk DeformingBulk DeformingManufacturing ProcessesManufacturing Processes
Bulk Deforming Simulation• http://www.afdex.com
© 2012 Su-Jin Kim GNU© 2012 Su-Jin Kim GNU
Bulk DeformingBulk DeformingManufacturing ProcessesManufacturing Processes
References• http://www.afdex.com• http://deform.co.kr• http://www.posco.co.kr