TOWARDS NETT-SHAPE MANUFACTURING OF TUBULAR COMPONENTS

This paper summarizes the results of work-in-progress research with a self developed two-step radial extrusion technique in which a simple p reforming operation has been added to the conventional radial extrusio n process. The proposed technique requires only simple modifications o f the tool. Finite element models conditioned from previous experiment s in aluminum served as a design tool for elaborating the process sequ ence and tool geometry which prevents the development of certain flow failures occurring in the traditional radial extrusion. Metal experime nts were performed to test the tool design. As. a result, it was possi ble to verify that the range of shapes that can be produced starting f rom a tube has been extended. Comparisons between theoretical predicti ons and experimental measurements obtained for a typical flanged compo nent are provided for material how, geometrical profile, effective str ain distribution and required forming load. Finally the potential of t he two-step radial extrusion technique is illustrated for the radial e xtrusion of a closed die shaped component.