Document Type: Research Paper


Production Technology Department, Faculty of Industrial Education, Beni-Suef University, Beni-Suef, Egypt



The Tube flange is typically performed using welding, forging method, both of which cost time and effort. In this work, a metal spinning process to form tube flange was proposed. A flange-forming tool was developed based on the outer tube diameter to form the flange. It consists of three components namely collet, mandrill and roller. An experimental study was carried out to form the flange of lead tubes. Several flanged specimens were conducted at different working conditions. These working conditions are rotating speed (rpm), feed rate (mm/rev), and wall tube thickness (mm). The effects of working conditions on the flanging loads were investigated. An experimental analysis was carried out to illustrate the effect of the working conditions on the characteristics of the tube flange. The analysis showed that these working conditions have a clear influence on wall thickness, surface hardness, and flanging loads. A theoretical analysis to model the flange forming loads (axial, radial and tangential) was present. A comparison between analytical calculated and experimental measured loads was discussed. This comparison indicates a good agreement between the deducted forces analytically, and that measured experimentally.

Graphical Abstract


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