In our series of studies, the outflow characteristics of a pressure medium used for a sheet hydroforming process have been investigated. The variation of hydraulic pressure during a square-cup sheet hydroforming process was examined, focusing on correlation with sheet deformation. In the initial stage, the outflow of the pressure medium remained stable because a greater extent of pre-bulging arose around the die shoulder just after the process commenced. When the pre-bulging ceased, the pressure medium was sealed in the chamber. Thus, the hydraulic pressure began to increase rapidly within the chamber, and fell in the flange area. The punch stroke at which the hydraulic pressure in the chamber began to rise was highly dependent on the blank holding force because the height of pre-bulging was determined by this force. When the sheet conformed completely to the die shoulder, the pressure medium was also sealed at the shoulder. Therefore, the hydraulic pressure on the die shoulder as well as in the flange area started to fall. The correlation between the critical punch stroke for fracture and the hydraulic pressure in the flange area was also examined.
The effect of the outflow volume of the pressure medium on the fluid-lubrication effect during the sheet hydroforming was investigated experimentally. The hydraulic pressures in the flange area obtained for the sheet hydroforming during which the hydraulic pressure was pressurized using pump were higher than those of the sheet hydroforming during which the pump was not utilized. This might be owing to the difference in the outflow volume of the pressure medium. On the other hand, the drawability of the sheet was almost independent of with or without using pump. Examining the so-called effective punch force, we found that the effect of the difference in the outflow volume of the pressure medium on the fluid-lubrication effect was negligible. We concluded from these results that the fluid-lubrication effect was affected significantly by the existence or non-existence of the outflow of the pressure medium, i.e. the lubricant oil, but it was almost independent of the outflow volume of the pressure medium. Furthermore we also found that the hydraulic pressure distribution in the flange area would not affect the fluid-lubrication effect.
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