Injection Forging of Thin-Walled Tubes

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.