Hmgf for boron manganese steels represents an innovative technique for manufacturing structural auto parts. Us20170341123a1 hot blow forming method for aluminum. The global market is booming because the rising vehicle production along with stringent emission norms and fuel economy regulations are driving the demand for lightweight materials in the. The properties of molybdenum based hot work steels is in between that of chromium based. The applications of aluminum alloys are limited due to the low formability at ambient temperature. Pdf simulation is a key topic within the development of the hot metal gas forming hmgf technology. Metal forming processes indian institute of technology. Iii defects introduced into metals during fabrication and service a. Driven by the objectives of reducing equipment size whilst forming complex shapes, hot metal gas forming hmgf was proposed and patented in the usa in 2001, which utilised pressurised gas medium to form hot metallic tubes. Research was concentrated on aluminium and titanium alloys aimed for the aerospace industry to address the poor ductility.
This improves the materials mechanical properties and workability. Aluminum alloys are considered a lot in the automotive and aerospace industry because of their high strength to weight ratio. In the last researches at fraunhofer iwu a combination of hot metal gas forming hmgf and press hardening has been used to form light weight parts made of manganeseboron steel tubes. In the paper new ways for increasing the forming limits of hot metal gas press hardening hmgph will be presented and shown on a demonstration part. Liu and wu 66 experimentally studied the hot metal gas forming of an az31 mg alloy tube, and they found that the inhomogeneous distribution by induction heating causes a different deformation mechanism. Sheetforming involves plane stress loading and lower forces compared to bulk deformation. Hot metal gas forming hmgf is a new metal forming process jointly developed by 15 automotiveaerospace companiessuppliers and one university under nistadvanced technology program 1, 2.
Defects introduced into metals during fabrication and service. A hot blow forming method for the aluminum alloy sheet carries out a hot blow forming to an aluminum alloy sheet using a first metal mold being a female mold for forming having a protruding surface portion on an inside surface thereof and a second metal mold for gas introduction. Theoretical and experimental investigations on press. Acetylene is a flammable fuel gas composed of carbon and hydrogen having the chemical formula c 2 h 2. In this paper, the hot metal gas forming for production of cylindrical step tubes from 6063 aluminum alloy is studied experimentally.
Hot metal gas forming hmgf is a new metal forming process jointly developed by 15 automotiveaerospace companiessuppliers and one university. Hot metal gas forming how is hot metal gas forming. This process is applied in the fabrication of dished heads for pressure vessels such as boilers. Hot metal gas forming of aluminum for manufacturing.
Neale encyclopedia of life support systems eolss the solidifying metal. Immediately prior to the hot blow forming, a temperature t 1 of the aluminum alloy sheet and a temperature t 2. In this manuscript, the gas forming process of aluminum aa6063 tubes at high temperatures up to 500c is investigated, through experimental and numerical tests. Hot isostatic pressing hip is a manufacturing process, used to reduce the porosity of metals and increase the density of many ceramic materials. For this purpose, taguchi method of experimental design was used to optimize the.
Hot metal gas forming hmgf of boronmanganese steel tubes. Applicable to most metal alloys, unique control over wall thickness has created a dramatic shift in. The high temperatures allow the metal to elongate, or stretch, to much greater degrees without rupture than are possible in. Heatform leads the industry in the application of warm forming or hot metal gas forming hmgf for hollow bodies. Here, a highoutput oxyacetylene torch is often the best way of heating the workpiece and producing transitions with optimum flow characteristics. Hot metal gas formingpress hardening experimental investigations 2. Experimental setup a demonstrator tool dp1 was used to form the provided tubes of ssab ab with a diameter of 57 mm and a wall thickness of 1. Mechanics of sheet metal forming college of engineering. They also studied feeding effect 27 on the hot gas forming of tubes tube. Hot working and cold working operatio slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. That is the ability to change without damage the shape and dimensions in hot and cold condition under the pressure of. Investigation of hot metal gas forming process of square parts m. Stainless steel tubes forming pdf, iddrg 2007 international conference, gyor, hungary, archived from the original pdf on 20110728.
Within the framework of investigations, an exhaust gas component made of titanium grade 2 was produced by means of hot metal gas forming hmgf at the fraunhofer iwu in chemnitz, germany. Fundamentals, processes and equipment for hot medium. Hot metal gas forming how is hot metal gas forming abbreviated. In gas welding, the filler metal rod is often coated with flux. Pdf investigation of hot metal gas forming process of. Chapter 17 4 sheetforming processes chapter 17 5 shearing operations shearing is the mechanical cutting of material without the formation of chips. When cold forming is not possible, technicians can hot form a part by heating it with a. A first stage where the volume of the part is generated a second stage where the. Hmgf is an outgrowth of superplastic forming spf and hot blow forming hbf techniques that the. Hot metal gas forming process for aluminium alloy tube. Hydroforming uses gaseous and liquid media in the cold or. Hmgf is a process that combines insitu induction heating of a tubular or flat. Request pdf on hot metal gas forming process hot metal gas forming hmgf is a new metal forming process jointly developed by 15.
Novel process chain for hot metal gas forming of ferritic. Hot forming press, tank head, dish head, vessel 3000ton press hot forming. Safety data sheet ghs product identifier other means of identification. A hot metal gas forming process for an aluminium alloy tube using sealing pressure and resistance heating was developed. Investigation of hot metal gas forming process of square parts. Sheet metal forming massachusetts institute of technology. Pdf multiobjective optimization of hot metal gas forming process to. The control of the hot gas bulging was simplified by sealing air in the tube. In this study, the effects of process parameters on the hmgf of aluminum alloy 6063 for the production of cylindrical stepped tubes were investigated through experimental tests and finite. Tearing criterion and process window of hot metal gas. Some of the original topics have been omitted or given in an abbreviated form in appendices. Optimization of hot metal gas forming by taguchi method. The hot metal gas forming hmgf process of aluminum was developed for manufacturing vehicle structural components.
Hot metal gas forming is an innovative metal forming technique with the potential to leapfrog conventional metal forming techniques of structural steel components for automotive and aerospace industry. The hip process subjects a component to both elevated temperature and isostatic gas pressure in a high pressure containment vessel. Metal forming market size, share, growth, trends, forecast. Hot forming is a unique metal forming processing technique. To overcome such limitations, hot metal gas forming is developed as a new process.
The application of a singlestage hotforming process, also referred to as hot metal gas forming hmgf, offers great potential to significantly reduce the production costs of such components. On hot metal gas forming process asme international mechanical. In recent years, enormous progress has been made in the analysis of forming of complex shapes using. Feasibility of fluxless reflow of leadfree solders in hydrogen and forming gas abstract an experimental study was conducted to investigate the feasibility of fluxless reflow of five tinbased, leadfree solders in hydrogen and forming gas 3% hydrogen balanced with nitrogen. Optimization of hot metal gas forming by taguchi method for. The hot forging manufacturing process and its undoubted. Semantic scholar extracted view of multiobjective optimization of hot metal gas forming process to production of square parts by mehrdad nasrollahzade et al. Sheet metal forming involves forming and cutting operations performed on metal sheets, strips, and coils. The process include heating of a rollformed tube in boron steel to 920 degc and subsequently blow and harden the tube into a structural component with yield strength of about 1100 mpa. In the developed process, the tube was heated during the forming, and thus the drop in temperature was prevented. Pdf hot metal gas forming process for aluminium alloy.
Pdf simulation and experimental results of the hot metal gas. Optimisation of condition in hot gas bulging of aluminium. C depending on customer specifications and the material used. In this process, the sealed tube is bulged by resistance heating without controlling internal pressure. Fundamentals of metal forming overview of metal forming material behavior in metal forming temperature in metal forming.
Hot metal gas forming hmgf is a new metal forming process jointly developed by 15 automotiveaerospace. Formability of aa6060 tubes in hot metal gas forming at high. Classification of basic sheet forming processes bending deep drawing shearing. Hot metal gas forming the next generation process for. The semifinished tubes were produced through direct hot extrusion, with different temperatures and feed. Hot forming is often an essential process step if collaring work is required. Hot metal gas forming hmgf with axial feeding presents unique features that enable the complex and further expansion of workpieces that are characterized by minimal defects, such as wrinkles and tears. Hot metal gas forming formblowing and hardening makes it possible to manufacture components with complex geometry and ultra high strength properties. The aim of forming quenchable highstrength steels at elevated temperature is not only to improve its forming properties like elongation and to reduce forming pressures. The surface areatovolume ratio of the starting metal is relatively high. Unesco eolss sample chapters materials science and engineering vol. Depending on the type of material being used, metal spinning can be considered both a cold and hot forming process. New developments in hot metal gas forming possibilities. Typically, metal spinning is used for producing parts like stainless steel bowls, satellite dishes, gas cylinders and brass instruments.
With its superior corrosion resistance capabilities, it has increasingly become the material of choice in the fabrication of chemical processing equipment. Chromium hot work steels h10, h11, h, h14 and h19 are the most commonly used for forging applications. In this paper the recently introduced technology of hot metal gas forming hmgf has been considered. The tube was bulged by thermal expansion of the air sealed in the tube without control of. The improvement of formability in tube hydroforming by. The initial temperature for hydrogen to effectively reduce tin oxides is around 400. Feasibility of fluxless reflow of leadfree solders in. Heatform warm forming or hot metal gas forming hmgf. Hot draw forming the hot forming process is similar to traditional cold forming but involves heating the tool and component. Metal joining process that uses melted metal as joints. Hmgf is an outgrowth of the superplastic forming process as used in the aerospace industry for forming low volume. The article describes a novel process chain for the hmgf process. Experimental and numerical investigation of the influence. Hot forming senior aerospace thermal engineering are.
Hot metal gas forming is a modern metal forming process which is generally utilized to manufacture automotive parts with complex shape and lightweight materials such as aluminummagnesium alloys. Plastic properties of metals are used during the process of metal forming. That is the ability to change without damage the shape and dimensions in hot and cold condition under the pressure of machining tools. Applicable to most metal alloys, unique control over wall thickness has created a dramatic shift in how complex products can be produced. A hot metal gas forming process for an aluminium alloy tube without and with axial feeding was carried out.
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