Tula State University, Tula, Russia

V. D. Kukhar, Dr. Eng., Prof.
S. S. Yakovlev, Assistant, e-mail: yakovlev-ss-science@yandex.ru
A. A. Shishkina, Postgraduate Student
S.D. Shekhovtsov, Master’s Student

This article examines the longitudinal corrugation of thin-walled steel cylindrical blanks using a local expansion method, which represents a promising alternative to traditional methods for producing complex-shaped parts, such as roller knurling, additive manufacturing, and pulse machining. The relevance of this study stems from the widespread use of corrugated tubular products in modern mechanical engineering and the need to develop high-performance manufacturing methods for them. The aim of this study is to investigate the influence of geometric process parameters (blank wall thickness and corrugation amplitude) on material damage and the likelihood of surface defects during longitudinal corrugation of thin-walled steel cylindrical blanks using local expansion, using numerical simulation. To achieve this goal, computer simulation was performed using the QForm software package, which implements the finite element method. Forming quality was assessed using two criteria: material damageability was determined using the Kolmogorov criterion, which characterizes the accumulated deformation and the risk of blank failure, and the likelihood of surface defects was assessed using the Hartfield criterion. The variable parameters were: blank wall thickness and corrugation amplitude with a constant number of corrugations; the blank material was grade 10 steel. Conclusions are drawn about the influence of the factors under consideration on the distribution and numerical values of damageability and the likelihood of defects. The study results indicate that in all cases examined, the stamping process proceeds without reaching a critical level of accumulated damage, confirming the technological feasibility of the longitudinal corrugation method for thin-walled steel blanks.

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