Injection forging of thin-walled tubes

IF 6.9 Q1 Engineering

International Journal of Lightweight Materials and Manufacture Pub Date : 2026-07-01 Epub Date: 2025-07-08 DOI:10.1016/j.ijlmm.2025.07.001

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

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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.

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薄壁管的注射锻压

本文提出了一种创新的注射锻造工艺，用于制造具有综合功能特征的净形薄壁管状件。该研究将有限元建模与模块化、灵活的注塑锻造工具的设计和构造相结合，从而实现小批量高效生产。在薄壁铝管上进行的实验证明了这种新概念的可行性和有效性，成功地形成了法兰宽度与管厚比为0.46的外环形法兰。这种新工艺通过消除二次连接或加工操作的需要，使生产具有改进结构性能的法兰成为可能。此外，新的注射锻造工艺通过提供一种具有成本效益的方法来制造轻质复杂管状部件，同时解决了当前与效率和材料利用率相关的行业挑战，从而促进了可持续制造的进步。

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