A new method for hydroforming of thin-walled spherical parts using overlapping tubular blanks

Han, Cong; Feng, Hao

doi:10.1007/s00170-019-04743-6

Cited by 3 publications

(2 citation statements)

References 19 publications

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“…It is not feasible to enhance the forming limit by increasing the axial feeding in this situation. Therefore, a novel approach was proposed, in which overlapping tubular blanks were used instead of closed cross-section tubes [18]. A sound spherical part with an expansion of 60.0% was obtained by using this approach, whereas the maximum expansion was only 46.1% using tubes with closed cross-sections.…”

Section: Samples and Materialsmentioning

confidence: 99%

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Circumferential Material Flow in the Hydroforming of Overlapping Blanks

Han

Feng

2020

Metals

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The hydroforming of the overlapping blanks is a forming process where overlapping tubular blanks are used instead of tubes to enhance the forming limit and improve the thickness distribution. A distinguishing characteristic of the hydroforming of overlapping blanks is that the material can flow along the circumferential direction easily. In this research, the circumferential material flow was investigated using overlapping blanks with axial constraints to study the circumferential material flow in the hydroforming of a variable-diameter part. AISI 304 stainless steel blanks were selected for numerical simulation and experimental research. The circumferential material flow distribution was obtained from the profile at the edge of the overlap. The peak value located at the middle cross-section. In addition, the circumferential material flow could be also reflected in the variation of the overlap angle. The variation of the overlap angle kept increasing as the initial overlap angle increased but the improvement of the thickness distribution did not. There was an optimal initial overlap angle to minimize the thinning ratio. An optimal thickness distribution was obtained when the initial angle was 120° for the hydroforming of the variable-diameter part with an expansion of 31.6%.

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Section: Samples and Materialsmentioning

confidence: 99%

“…In this paper, the circumferential material flow was investigated using overlapping blanks with axial constraints in the hydroforming of a variable-diameter part [19]. The shape of the variable-diameter part was cylindrical to guarantee that the expansion rates were equal at the bulging area.…”

Section: Introductionmentioning

confidence: 99%

Circumferential Material Flow in the Hydroforming of Overlapping Blanks

Han

Feng

2020

Metals

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Deformation behavior in the hydroforming of overlapping tubular blanks

Feng

Han

2020

International Journal of Machine Tools and Manufacture

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Deformation behavior in the tube hydro-pressing of rectangular cross-section components

Luan,

Zhuang,

Wang

et al. 2024

Preprint

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Tube hydro-pressing is a new ultra-low pressure forming method proposed in recent years to address the problem of ultra-high forming pressure required by conventional hydroforming processes in forming high-strength materials or extreme size components. It changes the conventional hydroforming method of die closing before bulging to pressing after filling with liquid, which significantly reduces the forming pressure and makes it possible to form high-strength materials or extremely small round radii and large-sized components. Wrinkling is the main defect in the tube hydro-pressing process, therefore, the key to forming is to control wrinkling. Based on this, a critical wrinkling theoretical model is established for tube hydro-pressing based on plastic strain theory and energy conservation theorem. Experimental and numerical simulation studies were conducted on tube hydro-pressing, and the effects of the internal pressure and the compression ratio on thickness distribution and fillet filling were discussed. The accuracy of the theoretical model was verified by the experimental results, and the process window for tube hydro-pressing of a rectangular cross-section component was obtained. The results indicate that the critical internal pressure for tube hydro-pressing depends on the strength coefficient, hardening index, and compression ratio. The thickness of the sidewall is related to the internal pressure and compression ratio, and the greater the internal pressure, the poorer the uniformity of the sidewall thickness. The greater the compression ratio, the thicker the sidewall. The maximum thickening of the hydro-pressed part reached 13.4% when the compression ratio is 4%. In addition, the larger the compression ratio, the smaller the fillet radius. A rectangular tube with a corner radius of only 3.0mm was manufactured when the compression ratio is 4%. It can be concluded that the critical wrinkling pressure theoretical model is effective in predicting wrinkling, which provides theoretical guidance for the tube hydro-pressing method, accurately predicts wrinkling defects, and ensures the realization of large compression ratios.

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A new method for hydroforming of thin-walled spherical parts using overlapping tubular blanks

Cited by 3 publications

References 19 publications

Circumferential Material Flow in the Hydroforming of Overlapping Blanks

Circumferential Material Flow in the Hydroforming of Overlapping Blanks

Deformation behavior in the hydroforming of overlapping tubular blanks

Deformation behavior in the tube hydro-pressing of rectangular cross-section components

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