COMPLAS 2025

Effects of Height Reduction Ratio of Multi-Pass on Forged Shape in Mandrel-Less Incremental Forging of Circular Tube End without Axial Feed

  • Makiyama, Takahiro (Institute of Technologists)

Please login to view abstract download link

This research focuses on the forging of circular tube end without axial feed in a proposed mandrel-less incremental forging. The proposed incremental forging is a more flexible forming process for producing tubes with variable cross-sections than conventional forming processes. Previous researches focused on the forging of the center of the tube in the axial direction, and revealed that the rotational feed defined by 2π/k rad·blow⁻¹, where k is odd number, is effective in reducing the outer diameter and reducing the ovalization[1], [2]. As a next step, it is necessary to study the forging of circular tube end without axial feed to provide a wide range of forged shapes. The outer diameter at the end of the tube with variable cross-section often requires a large reduction. Forging in a single pass, defined in this paper as k blows at the same height reduction ratio, may have limitations in reducing outer diameter. Therefore, the effects of multi-pass, composed of multiple single passes with different height reduction ratio, on the forged shape of the circular tube end were examined by conducting finite element simulation. For forged shapes, the differences between the maximum and minimum of each outer and inner diameter were evaluated as roundness. As the increment of the height reduction ratio in each single pass decreased, both the outer and inner roundness decreased at the same final height reduction ratio. By repeating the single pass at the final height reduction ratio after reaching the final height reduction ratio, the outer roundness was independent of the increment of the height reduction ratio in each single pass and the total number of blows decreased with increasing increment of the height reduction ratio in each single pass, and the inner roundness was a trade-off relationship between the total number of blows.