Access and use of this website and the material on it are subject to the Terms and Conditions set forth at Evaluating the flow stress of aerospace alloys for tube hydroforming process by free expansion testing Saboori, M.; Champliaud, H.; Gholipour, J.; Gakwaya, A.; Savoie, J.; Wanjara, P.http://nparc.cisti-icist.nrc-cnrc.gc.ca/npsi/jsp/nparc_cp.jsp?lang=fr L'accès à ce site Web et l'utilisation de son contenu sont assujettis aux conditions présentées dans le site LISEZ CES CONDITIONS ATTENTIVEMENT AVANT D'UTILISER CE SITE WEB. NRC Publications Record / Notice d'Archives des publications de CNRC:http://nparc.cisti-icist.nrc-cnrc.gc.ca/npsi/ctrl?action=rtdoc&an=21272131&lang=en http://nparc.cisti-icist.nrc-cnrc.gc.ca/npsi/ctrl?action=rtdoc&an=21272131&lang=fr READ THESE TERMS AND CONDITIONS CAREFULLY BEFORE USING THIS WEBSITE.http://nparc.cisti-icist.nrc-cnrc.gc.ca/npsi/jsp/nparc_cp.jsp?lang=en Vous avez des questions? Nous pouvons vous aider. Pour communiquer directement avec un auteur, consultez la première page de la revue dans laquelle son article a été publié afin de trouver ses coordonnées. Si vous n'arrivez pas à les repérer, communiquez avec nous à PublicationsArchive-ArchivesPublications@nrc-cnrc.gc.ca. Questions? Contact the NRC Publications Archive team atPublicationsArchive-ArchivesPublications@nrc-cnrc.gc.ca. If you wish to email the authors directly, please see the first page of the publication for their contact information. NRC Publications Archive Archives des publications du CNRCThis publication could be one of several versions: author's original, accepted manuscript or the publisher's version. / La version de cette publication peut être l'une des suivantes : la version prépublication de l'auteur, la version acceptée du manuscrit ou la version de l'éditeur. For the publisher's version, please access the DOI link below./ Pour consulter la version de l'éditeur, utilisez le lien DOI ci-dessous.http://doi.org/10.1007/s00170-014-5670-5International Journal of Advanced Manufacturing Technology, 72, 9-12, pp. 1275-1286, 2014 ORIGINAL ARTICLE Evaluating the flow stress of aerospace alloys for tube hydroforming process by free expansion testing Abstract In order to obtain accurate tube hydroforming (THF) simulation results, one of the important inputs in the finite element model (FEM) of the process is the mechanical response of the material during THF. Generally, the mechanical response is defined by the stress-strain behavior that can be determined from tensile testing of the specimens extracted either from the sheet used for roll forming of the tubes or directly from the tubes. More recently, free expansion testing has been used to characterize the mechanical response of the material for hydroforming applications. The free expansion test can emulate process conditions similar to those found during THF, and as such, can be used to obtain reliable and accurate information on the mechanical response/properties of the tubular material. The aim of this research is to present an approach for evaluating the s...
Tube hydroforming (THF) is an advanced metal forming process that is used widely in automotive industry, but the application of the THF process in aerospace field is comparatively new with many challenges due to high strength and limited formability of aerospace materials. The success of THF process largely depends on many factors, such as mechanical properties of the material, loading path during the process, tool geometry and friction condition. Due to complexity of this process, finite element modeling (FEM) can largely reduce the production cost. One of the important input in FEM is the material behavior during hydroforming process. The true stress-strain curve before necking can be easily determined, using either tensile testing or bulge testing, but for an accurate failure prediction in a large deformation, such as hydroforming, the study of true stress-strain curve after necking is important because it improves the quality of the analysis due to utilizing a real extended stress-strain curve. Hence, the objective of this research was to establish a methodology to determine the true stress-strain curve after necking in order to predict burst pressure in the THF of aerospace materials. Uniaxial tensile tests were performed on standard tensile samples (ASME E8M-04) to determine the true stress-strain before and after necking, using an analytical method presented in this study. To validate the approach, burst pressure in the THF process was predicted using the extended stress-strain curve in conjunction with Brozzo's decoupled fracture model. The approach was evaluated using data obtained from the free expansion (tube bulging) tests performed on stainless steel 321 tubes with 2 inches diameter and two different thicknesses, 0.9 mm and 1.2 mm. The comparison of the predicted and measured burst pressures was promising, indicating that the approach has the potential to be extended to predict formability limits in THF of complex shapes.
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