Analytical solution of the tooling/workpiece contact interface shape during a flow forming operation

TL;DR

This paper presents an analytical model for the steady-state contact interface in flow forming, validated experimentally, and adaptable to other rotary forming processes, offering a general and modifiable approach.

Contribution

It introduces a novel analytical model for the tooling/workpiece contact shape in flow forming, simplifying modifications of geometric variables compared to numerical methods.

Findings

Model accurately predicts contact interface shape

Experimental validation confirms model reliability

Applicable to various rotary forming processes

Abstract

Flow forming involves complicated tooling/workpiece interactions. Purely analytical models of the tool contact area are difficult to formulate, resulting in numerical approaches that are case-specific. Provided are the details of an analytical model that describes the steady-state tooling/workpiece contact area allowing for easy modification of the dominant geometric variables. The assumptions made in formulating this analytical model are validated with experimental results attained from physical modelling. The analysis procedure can be extended to other rotary forming operations such as metal spinning, shear forming, thread rolling and crankshaft fillet rolling.