Integral Hot Gas Pressure Forming of an AA2219 Aluminum Alloy Ellipsoidal Shell

Yuan, Shijian; Zhang, R.; Zhang, W. W.

doi:10.1007/s11837-017-2259-0

Cited by 2 publications

(1 citation statement)

References 11 publications

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“…Muller et al 11 expanded the research on the dieless hydroforming process for joining of oval cross-sectional profiles and observed that the strain distribution across the oval profile is not uniform 1 CAMM, Central Mechanical Engineering Research Institute, Durgapur, India 2 NDT, Central Mechanical Engineering Research Institute, Durgapur, India which results in heterogeneous bending stresses. Yuan et al 12 proposed integral hot gas pressure forming to make ellipsoidal shells out of Aluminium AA2219. Hummel et al 13 investigated dieless hydroforming for multilobe tubular structures and tested the process viability.…”

Section: Introductionmentioning

confidence: 99%

Evaluation of dieless hydroforming process for manufacturing of variable cross section tubular structures

Chandrasekar

Mukherjee

Singh

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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The dieless hydroforming is a type of manufacturing method that forms materials using pressurised hydraulic fluid rather than dies and presses as in traditional hydroforming, resulting in significant cost savings. The dieless hydroforming of tubular structures with variable cross section has received little attention, indicating that more research is needed in this area. Therefore, this article investigated dieless hydroforming of low carbon steel material with fluid pressures ranging from 10 to 50 bar and sheet thicknesses ranging from 1 to 2.5 mm to produce tubular structures with variable cross section. The main goal is to comprehend the deformation characteristics in relation to the parameters, as well as the impact of deformation on the microstructural and mechanical behaviour. The inflation and contraction patterns of hydroformed structures are numerically determined using the finite element method at various parameters and then compared to experimental results which show a good correlation. Plastic deformation induced grain refinement in all deformed samples, as compared to as-received material. The sample hydroformed at 30 bar and with a thickness of 2.5 mm showed higher yield strength (291 MPa), tensile strength (404 MPa) and elongation (48%) than the other samples. Hydroformed tubular structures with variable cross section are created and used in electric poles to hold solar panels after the process repeatability is tested and found to be highly repeatable with greater than 97% accuracy.

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