Work

Injection forging of thin-walled tubes

Year: 2025

Type: article

Abstract: This paper presents an innovative injection forging process designed for the manufacturing of net-shape thin-walled tubular components with integrated functional features. The research combines finite element modelling with the design and construction of a modular, flexible injection forging tool, allowing for efficient production in small batch sizes. Experiments conducted on thin-walled aluminium tubes demonstrate the feasibility and effectiveness of this new concept, showcasing the successful formation of external annular flanges with a flange width-to-tube thickness ratio of 0.46. This new process enables the production of flanges with improved structural performance by eliminating the need for secondary joining or machining operations. Additionally, the new injection forging process promotes advancements in sustainable manufacturing by offering a cost-effective way to fabricate lightweight complex tubular parts while addressing current industry challenges related to efficiency and material utilization.

Source: International Journal of Lightweight Materials and Manufacture

DOI: 10.1016/j.ijlmm.2025.07.001

Authors: J.P. Magrinho, M.F. Ferreira, P.A.F. Martins, M.B. Silva

Institutions: University of Lisbon, Instituto Superior Técnico, Instituto Superior Técnico Instituto de Engenharia Mecânica

Language: English

Topic: Metal Forming Simulation Techniques

Subfield: Mechanical Engineering

Field: Engineering

Domain: Physical Sciences

SDG: Industry, innovation and infrastructure

Open Access status: diamond

Funder: Fundação para a Ciência e a Tecnologia