Further assessment of the plastic instability of thin-walled tubes in double-sided hydro-bulging process with verification experiments

Abstract

An interesting process of double-sided tube hydro-bulging was proposed to provide a beneficial three-dimensional stress state in the deformation zone of the tube, so as to delay the occurrence of bursting on the tube. Previously proposed forming limit theory models with consideration of through-thickness normal stress found that the external pressure could lead to a deferred occurrence of plastic instability, but it has not been confirmed experimentally. In this article, the tensile plastic instability of tubes under double-sided pressures is further assessed based on the classical plastic instability theory. However, it is seen that the occurrence of plastic instability has not found delay when high external pressure was exerted on the outside surface of tube simultaneously, which is opposite to the previous forming limit models. In addition, an experiment investigation about double-sided tube hydro-bulging is conducted to verify the theoretical results, and the experimental results show that the external pressure has hardly any influence on forming limit strain of the 2A12 aluminum alloy tube before the occurrence of necking. Moreover, the contradiction between our results and the previously proposed forming limit theory models is that the previous models ignored the thickness item in the equilibrium equation.

Experimental Study of Hydroformed Al6061T4 Elliptical Tube Samples under Different Internal Pressures

“…[13]. Double-sided tube hydroforming-bulging was proposed by Xiao-Lei Cui to provide a beneficial three-dimensional stress state in the deformation zone of the tube, so as to delay the occurrence of bursting on the tube [16]. All the above proposed methods help in improving experimental design and setup of die and tooling.…”

A novel process of sheet metal inverse bulging pre-deformation for deep drawing forming using magnetorheological fluid as flexible media

“…3 However, the pressure of hydroforming can only be uniformly distributed on the sheet, and the viscous media needs to cleaning after forming process. 4–7 , and it is difficult to ensure the reliability of forming method by controlling blank holder force. 8…”

“…3 However, the pressure of hydroforming can only be uniformly distributed on the sheet, and the viscous media needs to cleaning after forming process. [4][5][6][7] , and it is difficult to ensure the reliability of forming method by controlling blank holder force. 8 In recent years, MR fluid has become a bridge to connect the energy field and soft die forming technology because of the special physical property.…”

A comprehensive damage criterion in tube hydroforming

“…7 Hydroforming method was originally invented to form aluminum tubes but, its usage was rapidly developed for other materials such as steel, 8 copper, 9 magnesium 10 and titanium. 11 Also, the tube hydroforming process is applicable to isotropic 12 and anisotropic 13,14 materials. It is interesting to know that the tube hydroforming method can be used for very small tubes.…”