Analytical model for tube hydro-forging: Prediction of die closing force, wall thickness and contact stress

Chu, Guannan; Chen, Gang; Lin, Chuang; Fan, Zhigang; Li, Hang

doi:10.1016/j.jmatprotec.2019.116310

Cited by 17 publications

(8 citation statements)

References 10 publications

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“…The tube hydro-forging technology is a new technological invention proposed by Harbin Institute of technology [11], which is based on the compression deformation. The cross-section is compressed and deformed by the die closing force, in which the internal pressure only plays a supporting role [12].…”

Section: Introductionmentioning

confidence: 99%

Development of New Hot Forming Process for High Strength Steel Tubes

Chen

Yin

Liu

et al. 2022

Proceedings of the 2022 International Conference on Smart Manufacturing and Material Processing (SMMP2022)

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The widely adopted the high strength steel tube is an important way to solve the lightweight body and collision safety. The traditional high pressure tube hydroforming and hot gas forming through “expansion” deformation to form hollow parts, and the internal pressure is the deformation driving force. There are some industrial difficulties such as heavy dependence on high pressure, wall thickness thinning and low production efficiency, which limits the production and application of high-strength steel tubes. Based on the principle of compression deformation, this paper develops the hot hydro-forging process to form the high-strength steel tubes. After the tube blank is heated to austenitization, the tube is compressed and deformed by the die closing force of the die through a new die structure. The internal pressure only plays a supporting role, which fundamentally avoids the thickness thinning and cracking under the expansion deformation mode, and has the advantages of rapid forming time and uniform quenching. Finally, the A-pillar tube with 1500 MPa is formed through the reasonable hot hydro-forging process.

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Section: Introductionmentioning

confidence: 99%

Development of New Hot Forming Process for High Strength Steel Tubes

Chen

Yin

Liu

et al. 2022

Proceedings of the 2022 International Conference on Smart Manufacturing and Material Processing (SMMP2022)

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“…In addition to many advantages, there were few disadvantages like high pressurisation and higher tonnage, and thus a low-pressure tube hydroforming was introduced, which dropped the fluid pressure to ~10% and tonnage to approximately less than half [29][30][31][32][33]. To further resolve the issue of thinning and pressure tube hydroforging was proposed [34][35][36]. In this process, the tube was bulging with internal pressure and then forge by movable dies.…”

Section: Introductionmentioning

confidence: 99%

A numerical analysis on microtube hydroforging

Nikhare

2021

Advances in Materials and Processing Technologies

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High-pressure tube hydroforming is a promising method to deform the tubes in various shapes by bulging the tube by applying high internal pressure. However, the challenges lie in the process itself, i.e., requires an expensive pump system and brings excessive thinning in the deformed part section. One option is to reduce the required pressure to solve these difficulties, and the other is to provide the axial feed to the tube in the deformation zone to reduce the thinning. However, due to the higher axial load, the tube buckles. This study is taking advantage of this buckling mechanic to convert it into a successful shaping option. This process is named as tube hydroforging. In this process, the tube was first bulged to a level using internal pressure in an open die without axial feed. Then a minimum pressure was applied, and dies were displaced to shape the tube. The paper studies the process for the microtube. The results noted that lower internal pressure is required to bulge the tube and either no internal or a minimum constant pressure to hydroforge the tube depending on the opening section and thickness of the tube.

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“…Studies have been performed mainly in contact problems with radially distributed modulus. Chu et al [ 15 ] developed a mathematical model to determine the strain and stress along the tube wall. Campos and Hall [ 16 ] provided a method with simplified Lamé's equations to accurately calculate the contact pressure and hoop stress between two contacting surfaces with alike material properties.…”

Section: Introductionmentioning

confidence: 99%

Contact stress prediction model of double‐layer elastomer with functionally graded and composite structure

et al. 2021

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As hard and brittle materials are widely used in the modern industry, it is essential to effectively achieve uniform material removal. In the present study, a contact stress prediction model for double-layer elastomer under uniform displacement load was proposed. It aims to predict the contact stress distribution based on the structure size and material parameters of the double-layer elastomer and optimize the relevant parameters to improve the uniformity of material removal. The functionally graded and composite structured lapping and polishing plate (FG/CS-LPP) was developed by mixing abrasive particles and rubber with different mass ratios to get different Young's moduli. Through optical microscope, the surface morphology was observed, and the mechanism of Young's modulus gradient change was demonstrated. After numerical simulation analysis, the effect of Young's modulus fluctuation on contact stress distribution trend was evaluated. As for the contact stress prediction model, an equivalent Young's modulus model and compensation function H(z) was introduced to simplify the analytical process. Further, the obtained equivalent equation was verified by simulations and experiments with an average percentage deviation of~2% and~6%, respectively. By fitting calculated and simulated values with a deviation of less than 5%, the compensation function H(z) was established. Finally, the contact stress prediction model was obtained and validated by simulations and experiments, the percentage deviation is less than 13%. Accordingly, the contact stress prediction model can provide a theoretical basis for FG/CS-LPP to achieve uniform material removal.

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Analytical model for tube hydro-forging: Prediction of die closing force, wall thickness and contact stress

Cited by 17 publications

References 10 publications

Development of New Hot Forming Process for High Strength Steel Tubes

Development of New Hot Forming Process for High Strength Steel Tubes

A numerical analysis on microtube hydroforging

Contact stress prediction model of double‐layer elastomer with functionally graded and composite structure

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