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The spring-back of a work-piece during machining operation causes dimensional error of the work-piece. In the present study, the spring-back of work-piece in ultrasonic-vibration assisted turning and conventional turning has been modeled. It is illustrated that the reaction of the work-piece in high frequency vibration cutting is similar to a static behavior, whereas the spring-back in this process is theoretically and experimentally smaller than the conventional cutting leading to smaller error. A method has also been proposed to obtain the errors caused by rigid assumption of the spindle assembly used for correction of the results.

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In this paper, cold roll forming process of a high strength steel pipe using four types of flower pattern including circular, edge, double radius and reverse bending is simulated with finite element method in MSC Marc Mentat software. Due to importance of quality of final pipe and in order to achieve the desired geometry in high strength steel pipes, selecting the appropriate flower pattern to design the pipe roll forming production line is considered. Using finite element simulation results, deformation of sheet in this process is studied and effect of flower pattern type on geometry of final product, which includes curvature distribution, spring back and thickness distribution of pipe, is investigated. Results show that implementing reverse bending flower pattern, leads to reduction in deviation from mean curvature at edge of the sheet up to about 65 percent. Thickness distribution analysis shows that circular and edge flower patterns cause upsetting and thinning of edge of the sheet up to 0.2 millimeters, respectively. But, use of double radius and reverse bending patterns cause average thickness of edge to be well adjusted to reach 2.8 millimeters. Also, circular flower pattern has the lowest value of spring back in terms of variation of mean relative curvature of 0.69 percent and edge deviation of 0.15 millimeters. To validate the finite element simulation, experimental tests were designed and conducted using one forming stand. By comparing resultant data of experimental tests with simulation results, validity of finite element simulation confirmed.

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At the end of the forming process, when the part is removed from the mandrel and the matrix and the part is loaded, a deformation occurs in the part, and this deformation after forming is called spring back. This research was carried out in order to experimentally determine the spring return of stainless steel 316 and carbon steel ST37 with different thicknesses in C-die forming and compare it with finite element simulation. The parts with three thicknesses of 1, 1.5, and 2 mm, forming and the geometrical dimensions of the spring back of the sheets have been verified. The results showed that the experimental spring back in the finite element simulation is consistent with the test, and also by reducing the thickness, spring back increases, which is affected by perfect elastic zone and surface plastic strain and membrane and bending stress.