Journal of Materials Processing Technology 170 (2005) 501–508

A rotary flange forming process on the lathe using a ball-shaped tool

Fouly A. Mohamed, Samy Zein El-Abden, Mohieldeen Abdel-Rahman ∗
Department of Prod. Eng. & Design, Faculty of Eng., Minia University, Minia 61111, Egypt

Received 10 May 2004; accepted 12 December 2004

Abstract

Flanging of tube ends is carried out using casting or assembly joining, which have drawbacks due to improper strength, defect generation or
low efficiency. In this work, flange forming of Al tubes was performed on the lathe utilizing a ball-shaped tool attached to the lathe carriage,
and fed outwards radially while the specimen clamped to the lathe chuck and rotated. Tubular specimens, were rotated at 500 rpm, and the tool
feed was 0.314 mm/rev. Ball diameter (Dball ) of 12.8 mm was fixed, while the tool advance distance (Ta ) at the start of flanging was 0.125, 0.25,
0.5, 0.625Dball . Oil was used as a lubricant. Results showed that the radial flanging force was increased as t0 and Ta increased. An approximate
contact area calculation was presented and the calculated loads were in agreement with the experimentally obtained ones. Relatively large
flanging ratios (FR) were obtained and those were found to increase as t0 decreases and Ta increases. Maximum thinning was observed at the
flange edge followed by an increase in thickness towards the area between the tube and flange. Surface hardness increased as t0 increased.
© 2005 Elsevier B.V. All rights reserved.

Keywords: Tube end flanging; Flanging load; Flanging ratio; Flange forming defects

1. The flange forming of tubes harden in a suitable manner. Some of the rotary forming pro-
cesses have limiting forming ratios less than conventional
Tube end flanges are necessary for the coaxiallity of tube processes (e.g. spinning compared to deep drawing) [5]. The
lines and easy tightening of joints [1]. Flanges can be obtained technique of using a rotary forming using a ball-shaped tool
by casting, assembly joining or forming. Forming, besides was successfully tried in tube end widening of tubes [6] and
material saving, usually improves the mechanical strength high limiting widening ratios (LWRs) and good mechanical
of the components. Some of these techniques however suf- properties were obtained.
fer from improper strength and defect generation. Some
advanced methods were successfully used. In El-Sheikh’s
work [2], flanging was supported by a cylindrical roller and 2. Analysis
high flanging ratios (FR) were obtained. Limiting flanging
ratios (LFR) achieved were 1.27 for annealed aluminum and In simple case of the rotary upsetting of flanges, the mate-
1.475 for annealed lead. These LFR values are considered rial element is considered under the plane strain upsetting
high but they are expected because of the nature of stress state [1]. The normal force acting on the contact area between
state when using a side and back supports. This means an flanging ball and the tube wall is given by the stress multiplied
addition of a compressive hydrostatic stress to the stress state by the active area, and:
on the surface which helps in delaying fracture [3]. Possi-
ble defects in such process are: flange wrinkles, edge cracks Stress = Kεn (1)
and tearing or wall splitting. Rotary forming is characterized

2
by the small contact area during forming, in other words the Effective strain, ε = εf (2)
deformation is done incrementally[4]. This gets the advan- 30.5
tage of less load and enables each element to deform and  
Dflange final
Strain, εf = ln (3)
∗ Corresponding author. Dinner of the tube

0924-0136/$ – see front matter © 2005 Elsevier B.V. All rights reserved.
doi:10.1016/j.jmatprotec.2004.12.017
502 F.A. Mohamed et al. / Journal of Materials Processing Technology 170 (2005) 501–508

Fig. 2. (a) Contact area in flange forming. (b) A sector of contact between
the tool and the tube.

all geometry of the specimen other than contouring of the

top surface. The process of deformation, the contact area
between the forming tool (ball) and the workpiece in flang-
Fig. 1. A proposed mode of deformation in tube flanging. ing of tubes are shown in Fig. 2a and b. Assumptions were
made to simplify the calculation as follows: the centerline
of the ball coincides with the outer diameter of the tube; the
A proposed mode of deformation in outward flanging
thickness does not change. Consider an arbitrary portion of
while the specimen is rotated is presented in Fig. 1. The
the deformed flange contacting with the form tool in position
possible three stages are as follows. Stage 1 (steps 1–3): is
one. When the forming tool advances in the radial direction
a preliminary upsetting stage. Aided by the outward feed
by the value of the outward feed, the contact area will be
applied from the lathe carriage, the ball-shaped tool tries first
obtained by the tool movement path when it moves from the
to overcome friction and generates radial stress. When such
first to the second position. The acting contact area, however,
stress reaches the specimen material yielding point, a com-
is approximately a half segment of a sphere along arc AB
pressive strain on the inner fibers and a tensile one on the
at the front of the forming ball while the other half of the
outer fibers are developed. Reaching this point, an upsetting
sphere along the arc BL at the rear of the form tool is free
mode in the tube wall causes an amount of material to be
from contact. From Fig. 2b,
compressed radially. Since there is no reaction on the free
surface (outer diameter of the tube), a radial movement is BC2 = AC2 + AB2 − 2AC · AB cosθ (4)
about to begin.  
Stage 2 (steps 4–8): is a bending mode of deformation AC2 + AB2 − BC2
cosθ = (5)
of the contact area with the ball, at which the material is 2AC · AB
pushed outwards 90◦ to the tube axis. In this stage, the vol-
 
ume is displaced outwards and the side volume is still partially AC2 + AB2 − BC2
deformed. The formed land is relatively high at first and then θ = cos−1 (6)
2AC · AB
reduces as the metal flows radially. The tool at the begin-
ning of this stage is in contact with the full thickness of the y = AC − AC cosθ + twp (7)
tube. This is changed after the tool continues to be pushed
outwards until it leaves that contact finally at step 7. Stage 3 AC = Rwp in + Rball (8)
(steps 9–10): at which the tool reaches its end contact with
the specimen. The area of contact decreases until reaching or
zero at the end, leaving the flange.
y = (Rwp in + Rball )(1 − cosθ) + twp (9)
To determine the contact area during the indentation phase
of the process, the movement of the displaced volume is
assumed to cause only an insignificant change in the over- CL = 2AC sinθ
 F.A. Mohamed et al. / Journal of Materials Processing Technology 170 (2005) 501–508
Fig. 3. Tooling arrangement used in flange forming, 1—casing; 2,3—bearing; 4—bolt; 5—pin; 6—shank; 7—weld; 8—ball; 9—specimen; 10—3-jaw chuck;
11—plug; 12—tool post; 13—shank; 14—plate; 15,16,17—starin gauges; 18—lathe jaw chuck.
and
C L = 2AC sinθ + 2twp = 2(Rwp in + Rball ) sinθ + 2twp
(10)
π
gage bridge was used to measure the radial force.
{C L + 4(y + v)2 }
2
Area = (11)
4
π
Aactive = 0.5 {C L + 4(y + v)2 }
2
(12)
4
where Rball , ball radius; Rwp in , inner workpiece radius; twp ,
workpiece thickness = flange thickness.
3. Experimental work
Tests were carried out on a 8 kW ZMM universal lathe,
type CY630. Commercial purity Aluminum (in the as-
received condition) was used originally received in form of
seamless tubes, 23 mm outer diameter and 10 mm inner diam-
eter. Fixed specimen rotating speed (500 rpm) and outward
radial tool feed (0.314 mm/rev) were chosen optimized from
a recent publication of the authors [7] to get the best surface
quality. Specimens having a fixed inner diameter (13 mm) and
varying tube initial thickness (t0 ) of 2, 2.5, 3.0 and 3.5 mm
were prepared on a center lathe and finished using a sand
paper up to a grade 600. The specimen length fixed as 30 mm
and the free length was 15 mm. Oil was used as a lubricant.
Advance distance (Ta ) of the tool at the start of flanging were
varied to be 0.125, 0.25, 0.5, 0.625 of the flanging ball diam-
eter (12.8 mm). The tool was adjusted at the center of the
tube bore and then the lathe chuck was rotated then the cross
feed is applied. Tooling arrangement used for flange forming
503
is shown in Fig. 3. The set up is similar to that described in
detail in Ref. [6]. The shank carrying the ball-shaped tool
was shortened as possible to avoid bending. Self-adjusting
was assured using a dial gage to ensure the coaxiality. Strain
4. Results and discussions
4.1. Radial force
Fig. 4a gives the maximum radial force values in flang-
ing for different t0 and Ta values. It is clear that the measured
flanging load increases as the t0 and Ta increase. This increase
is referred to the increasing volume which should be dis-
placed by the tool in this case. Also, the increase in Ta results
in applying greater contact area which leads to an increase in
force. A test was done to evaluate the validity of the area cal-
culation in calculating the flanging load. The case of flanging
with Ta = 0.5Dball was chosen. Equivalent true strains were
found to be 0.809, 0.767, 0.79 and 0.825 for t0 values of 2, 2.5,
3 and 3.5 mm respectively. Assuming that the contact distance
with the ball at the inner diameter = 0.35 of the inner diame-
ter, then the mean angle can be calculated as half of the sum
of the two values: 0◦ and 18◦ . A plot of the radial force versus
t0 is presented in Fig. 4b. An agreement is shown between
the calculated and the experimentally obtained results.
4.2. Flanging ratios (FRs) achieved
Flanging ratios (FRs) achieved in the rotary flange form-
ing process changed by changing t0 and Ta , as shown in
504 F.A. Mohamed et al. / Journal of Materials Processing Technology 170 (2005) 501–508
Fig. 4. (a) Radial force vs. initial tube thickness. (b) Calculated (dashed) vs.
the experimental load for Ta = 0.5Dball for different thicknesses.
Fig. 5. FRs were higher as t0 and Ta increase. The increase
in the volume of the material in front of the tool means a
larger diameter, i.e., larger FR. Increasing the t0 , the mate-
rial is more rigid which means eliminating defects. But on
the other hand when the t0 increased, more hardening is
expected and consequently difficulty in flowing results, lead-
ing to 2-level flow in the flange plane. Crack initiation in the
flange is referred mostly to tensile stresses generated, leading
to edge cracking followed by propagation and finally split-
ting. The 2-level flow leads to more thinning and accelerates
the crack initiation. For Ta = 0.125Dball , FRs achieved were
1.504, 1.73, 1.769 and 1.865 for t0 = 2, 2.5, 3 and 3.5 mm
respectively. For Ta = 0.25Dball , FRs were 1.8, 1.83, 1.84 and
1.88 for the same above thickness values. Corresponding
FRs for Ta = 0.375Dball were increased to 1.98, 2.02, 2.11
and 2.22 respectively, while for Ta = 0.5Dball , FRs were 2.24,
2.15, 2.16 and 2.28. For the largest Ta (0.625Dball ), FRs
were 2.27, 2.37, 2.43 and 2.66. Limit flanging ratio (LFR)
was considered as cracks or tears were developed. For the
Fig. 5. Flanging ratios (FR) vs. the initial tube thickness in flanging.
Ta = 0.125Dball , all the formed specimens were successful,
except the one having 3.5 mm and FR of 1.865 in which the
specimen had a 2-level flow. For Ta = 0.25Dball , LFR was 1.88
for t0 = 3.5mm, accompanied by 2-level flow plus beginning
of cracking on the flange edge. For Ta = 0.375Dball , the LFR
was 2.227 for t0 = 3.5 mm, accompanied by 2-level flow plus
apparent cracking on the edge. Bad finish was also detected
on the flange area. The same conditions were obtained for
the Ta = 0.5Dball , but the LFR was 2.28 for t0 = 3.5 mm. For
the largest Ta (0.625Dball ), the LFR was 2.43, for t0 = 3 mm,
with bad finishing and wrinkles. Complete tearing of the
flange was only noticed at LFR of 2.66 for a 3.5 mm thick
specimen. LFRs achieved in this work are considerably good
compared with these achieved by El-Sheikh [2] with using
support rollers.
4.3. Strains and hardness in flanged parts
When interpreting experimental results on tube flanging,
it is important to establish the amount of longitudinal
shortening (i.e. drawing in) of the tube that has taken
place. In similar cases (with simple hydraulic bulging for
example), longitudinal shortening of the tube is small and
the assumption of pure stretch forming is probably a good
approximation [8]. The axial strain was measured after
forming as ln(final tube length/initial length) and plotted
versus t0 in Fig. 6. Such strains ranged from 0.034 to 0.246.
Generally, shrinkage strain increased as the Ta increases
for the same t0 . This is due to the increase in volume
displaced by the tool. The effect of thickness can be taken
from the general trend, declaring that there is a decrease in
shrinkage strain as t0 increases, increase in metal in front
 F.A. Mohamed et al. / Journal of Materials Processing Technology 170 (2005) 501–508
Fig. 6. The axial tube length shrinkage strain vs. the initial tube thickness.
of the tool, makes the metal flow more difficult. The hoop
strain (ln(flange diameter/tube bore)) versus the initial tube
thickness is given in Fig. 7. The smallest value was 0.14, the
largest one was 0.57. Generally, hoop strain of flanged parts
Fig. 7. The hoop strain vs. the initial tube thickness.
505
Fig. 8. Mean thickness vs. the initial tube thickness.
was noticed to increase as t0 decreases and Ta increases.
Increase in Ta leads to more volume required to be formed
and higher FR while decreasing the t0 means an increase in
the outer tube diameter, leading to higher hoop strain.
Mean thickness strain was calculated from the volume
constancy principle. The result is given in Fig. 8. Maximum
thickness strain of flange was noticed to decrease as t0 and
Ta increase as shown in Fig. 9. This is a result of the increase
Fig. 9. The maximum thickness strain vs. the initial tube thickness.
506 F.A. Mohamed et al. / Journal of Materials Processing Technology 170 (2005) 501–508
Fig. 10. A sample of thickness strain distribution of a flanged part.
in FR, higher flange diameter and higher amount of thinning.
Maximum thickness was found beside the intersection of the
flange with the tube wall. The smallest value was 0.19, and
the largest one was 0.84. A sample of the thickness distri-
bution on a flanged part is given in Fig. 10. Four points of
hardness measurements were taken on the face of the formed
flanges. An increase in hardness was noticed proportional to
t0 . Fig. 11 shows the development of hardness with t0 for Ta
Fig. 11. Development of hardness with tube thickness.
Fig. 12. Photos of some sound specimens, Ta = 0.125Dball , from left t0 : 2,
2.5, 3, 3.5 mm, FR: 1.504, 1.723, 1.79, and 1.856.
of 0.375Dball . An increase reaching about 49% was achieved
which means that the forming process gave an improved hard-
ness property for the flange.
4.4. Defects of flanged ends
Sound products were obtained up to FRs of 1.769
for t0 = 3 mm and Ta = 0.125Dball , 1.84 for t0 = 3 mm and
Ta = 0.25Dball , 2.115 for 3 mm and 0.375Dball , 2.15 for 3 mm
0.5Dball, and finally 2.37 for 2.5 mm and 0.625Dball . Sound-
ness of the formed flanges depends mainly on both t0 and
Ta . As t0 increases, more instability was developed. How-
ever this can not be generalized to develop an optimum value
of (diameter/t0 ). This may lead to decrease the utilization of
the material. But it is suggested that reaching such reasonable
FRs be fairly good when larger diameters are used. Fig. 12
shows photos of some sound specimens, Ta = 0.125Dball and
t0 = 2, 2.5, 3, and 3.5 mm. The obtained FR values were 1.504,
1.723, 1.79 and 1.856 respectively. Buckling was noticed in
large free lengths (more than 15 mm) for the 30 mm long spec-
imen (original length). So it can be recommended to increase
the free length than 0.5 of the initial tube length to avoid buck-
ling. Orange peeling and wrinkles were noticed on the reverse
side of the flange at largest Ta due to larger amount of mate-
rial displaced. The stress state at this part is compressive and
helps to form the peels. An example of the peels are shown
in Fig. 13 at Ta = 0.5Dball and t0 = 2.5 mm, FR = 2.153. Very
small flange edge cracks are also noticed and this is caused
by more pile up of the material due to increase in volume of
the material.
Flange edge cracking appeared at large t0 values and
relatively moderate Ta . An example is given in Fig. 14
for Ta = 0.375Dball , and t0 = 3.5 mm. Many small cracks are
formed at the flange edge. The product is compared to those
with t0 = 2.5 and 3 mm (sound) for the same Ta , Fig. 15.
At the largest Ta (0.625Dball ), and t0 = 3.5 mm, longitudi-
nal wall split was noticed. It was found that this split began
at the flange edge and the failure was activated by the ten-
sile state of stress generated. Explained by Ahmed et al [9],
 F.A. Mohamed et al. / Journal of Materials Processing Technology 170 (2005) 501–508
Fig. 13. Peeling on specimen surface. Ta = 0.5Dball , from left: t0 = 2 mm and
3 mm, FR = 2.246 and 2.135.
Fig. 14. Edge cracking, Ta = 0.375Dball , t0 = 3.5 mm, FR = 0.227.
work hardening resulting from deformation encourages the
possibility of forming small cracks and further deformation
leads to a local thinning and this continues until final split-
ting. In this case it was noticed that the maximum thickness
reduction was in the front edge of the flange and hence the
possibility of beginning splitting is greater. An example of
flange splits is given in Figs. 16 and 17 for Ta = 0.625Dball
and t0 = 3.5 mm giving LFR of 2.665. The product had severe
Fig. 17. Product of Fig. 16: (left) compared to a specimen, t0 = 2.5 mm, FR = 2.375.
507
Fig. 15. Product shown in Fig. 14: (right) compared to two sound specimens,
FR = 3.2 and 2.115.
Fig. 16. An example of splits, Ta = 0.625Dball , t0 = 3.5 mm, LFR = 2.665.
cracking, bad finish and irregular material distribution. To the
right, appears another specimen having t0 = 2.5 mm and FR
of 2.376 at the same working conditions. The latter specimen
had bad finish but no splits were found. The 2-level forming
is referred to the large amount of material built up in front of
the tool and with the insufficient time for the material to fill
the intended position in the flange, the phenomenon appears.
The 2-level forming was noticed in many cases in the present
work. Generally, it developed as the t0 increased irrespective
of Ta . However, the severity of the 2-level flow appears to
increase as distance increase. A sample is given in Fig. 18 for a
specimen having Ta = 0.625Dball and t0 = 3.5 mm giving LFR
of 2.665.
508 F.A. Mohamed et al. / Journal of Materials Processing Technology 170 (2005) 501–508
Fig. 18. Two-level flow: Ta = 0.625Dball , t0 = 3.5 mm, LFR = 2.665.
5. Conclusions
From the scope of the present results, the following con-
clusions has been made:
1. A rotary flange forming of tube ends was carried out on
the lathe using a simple ball-shaped tooling, and proved
to be successful.
2. Increasing initial tube thickness and tool advance distance
at the beginning of the process proved to increase the load
required for flanging.
3. High flanging ratios could be obtained for high initial tube
thickness and large advance tool distance.
4. Defects concentrated in wall splitting and some bulging
and buckling.
5. The deformed part had improved hardness properties.
Some thinning was noticed especially at the flange edge.
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