The objective of this study is to improve the bulging and minimize the thinning ratio to enhance manufacturing of components in Industries. Tube hydroforming is an advanced manufacturing technology used for making intricate and complex tubular parts which required less cycle time. This research focuses on hydroforming process, formability and process parameters design to replace the conventional tube bending, welding and cutting operations. The prediction of parameters is done by applying numerical and experimental approach. During experimentation the pressurized fluid is used to deform the tubes in a plastic deformation. In this study, two types of grade materials are used such as AISI304 and AISI409L of 57.15 mm external diameter with 1.5 mm thickness in the form of electric resistance welded tubes to measure stain path, thinning and bulge height. However, it is observed that the internal pressure and L/D ratio are effective parameters in both numerical analysis and experimentation. In axial feed condition, it is observed that 16.3% thinning in weld region and 44.6% thinning in base metal region, whereas, in fixed feed condition, it is observed that 7.7% thinning in weld region and 18.6%thinning in base metal region for L/D = 1 and L/D = 3 respectively. The numerical analysis with experimental results shows a very good match. It is seen that the axial feed leads to better formability with fixed feed condition because in axial feed condition material supplies towards the center of the bulge tube. The feasibility of the hydroforming process for manufacturing of AISI304 and AISI409L grade material as per the requirements of the industries is also checked. The maximum bulging is observed in L/D = 2 by comparing with the other ratios. This process can be effectively used for AISI304 grade material because the formability is better than AISI409L. Article highlights The strain path measured and predicted at necking point for ERW tube in both weld and base metal. Thinning is measured during bulging of tube under the axial and fixed feed condition. For L/D = 1 ratio observed strain distribution in unidirectional and L/D = 2, 3 observed in plane strain and bidirectional respectively.
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The automotive industries are trying to optimize the forming and process parameters to reduce the weight of vehicle. Also, these optimized results are helpful to the manufacturer during decision making, so that overall product development or manufacturing time is reduced. In this paper, comparison of the strain paths, necking and fracture behaviors among the steel materials is performed. In this paper, the formability parameters such as strain path, thinning and contact pressures between die sets are studied. The strain path points are predicted by using FEA simulation in Pamstamp software for AISI304 and AISI409L grade material. The major and minor points are predicted at necking points for various specimens and these points are represented on FLD curve for both the materials. It is observed that AISI304 grade material showed higher formability i.e. 17% higher formability than the AISI409L grade material. The simulated and experimental results showed a closed match with good correlations though the variation between them is nearly 7%. Also, the microstructures are investigated by following standard metallographic process and after investigation it is observed that as the microstructure changes the locations of the deformed sheet parts also get changed.
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