Experimental and numerical study on hydroforming characteristics of friction stir welded aluminum alloy tubes

Hu, Zhang; Wang, X. S.; Pang, Qiu; Huang, Feng; Qin, Xunpeng; Yuan, Shijian; Hua, Lin

doi:10.1007/s00170-014-6613-x

Cited by 5 publications

(3 citation statements)

References 25 publications

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“…The thickness distribution greatly depends on the sequence of the contacting die and the variations of the curvature radius of the tube during hydroforming. Moreover, the weld shows an inhibitory effect for the generation of the wrinkles and decreases the number of the wrinkles as compared to the seamless tube during hydroforming [57].…”

Section: Aluminum Alloy Behavior During Hydroforming Processmentioning

confidence: 98%

Aluminum Alloys Behavior during Forming

Ramulu¹

2020

Aluminium Alloys and Composites

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Industrial revolution toward weight reduction and fuel efficiency of the automotive and aerospace vehicles is the major concern to replace heavy metals with light weight metals without affecting much strength. For this, aluminum alloys are the major contributors to those industries. Moreover, aluminum alloys are majorly categorized as 1xxx, 2xxx, 3xxx, 4xxx, 5xxx, 6xxx, 7xxx, and 8xxx based on major alloying elements. Among all, 2xxx, 5xxx, 6xxx, and 7xxx are having majority of applications in the abovementioned industries. For manufacturing any engineering deformable components, forming characteristics are must. Forming behavior of aluminum alloys has been evaluated through different processes including deep drawing, stretching, incremental forming, bending, hydro forming etc., under different process conditions (cold, warm, and hot conditions) and process parameters. Each process has its own process feasibility to evaluate the formability without any forming defects in products. The present chapter discusses a few important processes and their parameter effect on the aluminum alloys through the experimentations and simulation works.

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Section: Aluminum Alloy Behavior During Hydroforming Processmentioning

confidence: 98%

Aluminum Alloys Behavior during Forming

Ramulu¹

2020

Aluminium Alloys and Composites

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“…The hydro-formability of friction stir-welded (FSW) aluminum alloy tubes is investigated, and the hydroforming performance of the FSW tubes was mainly investigated by die-bulge forming with fixed ends. It is found that hydro-forming FSW aluminum alloy tubes is a new deal and does show a few peculiarities [15]. A tube bulging test was proposed, and the theory was introduced.…”

Section: Introductionmentioning

confidence: 99%

Pre-form design for hydro-forming of aluminum alloy automotive cross members

Cai

Wang

Yuan

2015

Int J Adv Manuf Technol

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Due to the requirement of lightweight in the automotive industry, aluminum alloy components with irregular cross sections have been used for body-in-white parts. In order to obtain an aluminum alloy cross member with uniform thickness distribution and acceptable dimension accuracy, a hydro-forming process of a 6063-T4 aluminum alloy cross member was studied by experimental research and numerical simulation. To avoid severe thinning and bursting during hydro-forming, the design of experiments according to a central composite design method was carried out, and the significance of pre-form structural parameters was discussed on thinning. According to the optimum pre-form shape, experimental researches were then conducted on thickness distribution of typical sectional profiles and dimension accuracy. It is shown that the maximum thinning is 14 %, which is located on sectional profile B-B. The deviation of circumferential dimension accuracy along the axial direction is 0.33 %. The maximum dimensional deviation at sectional profiles A-A and B-B is 0.19 and 0.22 mm, respectively; accordingly, the dimension accuracy along the width direction is 0.4 and 0.31 %, respectively. Finally, a sound hydro-formed cross member is obtained.

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“…In order to meet the demand of the fuel efficiency and emission reduction, aluminum alloy is widely used in the aerospace and automobile industries for its advantages of high strength-to-weight ratio, excellent corrosion resistance, and good weldability [1][2][3]. However, it is difficult for the aluminum alloy to form a complex shape part due to the poor formability at room temperature.…”

Section: Introductionmentioning

confidence: 99%

Analysis of thickness variation of reverse deep drawing of preformed 5A06 aluminum alloy cup under different temperatures

Zhang

Yuan

2015

Int J Adv Manuf Technol

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Warm reverse deep drawing of 5A06 aluminum alloy under differential temperature was conducted experimentally to investigate the effect of the temperature value and gradient on the deformation behavior. With an initial temperature value of 300°C in the flange region, three temperature gradients (the temperature difference between the flange region and the center of blank) of 185, 100, and 25°C were adopted. It is shown by the experimental results that the thinning ratio at the punch corner increases from 1.4 to 4.6 % with the temperature gradient decreasing from 185 to 25°C, which implies that the thinning can be reduced with temperature gradient increased. Keeping the temperature gradient being 100°C, reverse deep drawing experiments were conducted under different temperature values of 200, 300, and 400°C in the flange region. The thinning ratio at the punch corner increases from 3.1 to 5.9 % with the temperature increasing from 200 to 400°C, which indicates that the thinning can be reduced by decreasing initial temperature. Moreover, fracture occurs at temperature above 300°C with even temperature in the blank, and it can be avoided with differential temperature in the blank, which implies that a higher forming temperature was allowed when a temperature gradient was imposed in the blank.

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Experimental and numerical study on hydroforming characteristics of friction stir welded aluminum alloy tubes

Cited by 5 publications

References 25 publications

Aluminum Alloys Behavior during Forming

Aluminum Alloys Behavior during Forming

Pre-form design for hydro-forming of aluminum alloy automotive cross members

Analysis of thickness variation of reverse deep drawing of preformed 5A06 aluminum alloy cup under different temperatures

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