Numerical and experimental study of bursting prediction in tube hydroforming of Al 7020-T6

Afshar, A.; Hashemi, Ramin; Madoliat, Reza; Rahmatabadi, Davood; Hadiyan, Behzad

doi:10.1051/meca/2017019

Cited by 14 publications

(8 citation statements)

References 22 publications

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“…The remaining simulation conditions are listed in Table 3. For numerical prediction of the failure, the second derivative of equivalent plastic strain criterion was employed, as Afshar et al [18] successfully used to predict the failure onset of the 7020-T6 aluminum tube in hydroforming process. In this method, it is assumed that failure occurs when the second derivative of the plastic strain reaches its maximu m value.…”

Section: Finite Element Simulationmentioning

confidence: 99%

Improvement of Die Corner Filling of Stepped Tubes Using Warm Hybrid Forming

Ahangar

Bakhshi-Jooybari

Hosseinipour

et al. 2019

IJE

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Section: Finite Element Simulationmentioning

confidence: 99%

Improvement of Die Corner Filling of Stepped Tubes Using Warm Hybrid Forming

Ahangar

Bakhshi-Jooybari

Hosseinipour

et al. 2019

IJE

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“…The strain non-uniform index and forming limit diagram are good methods to identify the defect free components by simulation [37]. The fracture and necking parameters were analysed numerically and observed that the static pressure was increased which led to shifting the fracture area from P to C type shaped tubes [38], whereas the forming limit diagram was drawn at necking points of bulged tube with experimentation and simulation on AL-7020-T6 material grade [39].…”

Section: Introductionmentioning

confidence: 99%

Predictions of formability parameters in tube hydroforming process

Marlapalle¹,

Hingole²

2021

SN Appl. Sci.

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The objective of this study is to improve the bulging and minimize the thinning ratio to enhance manufacturing of components in Industries. Tube hydroforming is an advanced manufacturing technology used for making intricate and complex tubular parts which required less cycle time. This research focuses on hydroforming process, formability and process parameters design to replace the conventional tube bending, welding and cutting operations. The prediction of parameters is done by applying numerical and experimental approach. During experimentation the pressurized fluid is used to deform the tubes in a plastic deformation. In this study, two types of grade materials are used such as AISI304 and AISI409L of 57.15 mm external diameter with 1.5 mm thickness in the form of electric resistance welded tubes to measure stain path, thinning and bulge height. However, it is observed that the internal pressure and L/D ratio are effective parameters in both numerical analysis and experimentation. In axial feed condition, it is observed that 16.3% thinning in weld region and 44.6% thinning in base metal region, whereas, in fixed feed condition, it is observed that 7.7% thinning in weld region and 18.6%thinning in base metal region for L/D = 1 and L/D = 3 respectively. The numerical analysis with experimental results shows a very good match. It is seen that the axial feed leads to better formability with fixed feed condition because in axial feed condition material supplies towards the center of the bulge tube. The feasibility of the hydroforming process for manufacturing of AISI304 and AISI409L grade material as per the requirements of the industries is also checked. The maximum bulging is observed in L/D = 2 by comparing with the other ratios. This process can be effectively used for AISI304 grade material because the formability is better than AISI409L. Article highlights The strain path measured and predicted at necking point for ERW tube in both weld and base metal. Thinning is measured during bulging of tube under the axial and fixed feed condition. For L/D = 1 ratio observed strain distribution in unidirectional and L/D = 2, 3 observed in plane strain and bidirectional respectively.

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“…Alzahrani et al [1] analytically modeled a multi-nose symmetric tube in the hydroforming process based on a mechanistic approach. Afshar et al [2] investigated the forming limit diagrams of hydroformed aluminum tubes to predict bursting, and they compared the numerical results with experimental tests. Keigler et al [3] enhanced the formability of aluminum components via warm hydroforming, and they studied the effect of temperature controlling on wall thickness and microstructure before and after the forming process.…”

Section: Introductionmentioning

confidence: 99%

Hot Gas Forming of Aluminum Alloy Tubes Using Flame Heating

Talebi-Anaraki

Chougan

Loh-Mousavi

et al. 2020

JMMP

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Hot metal gas forming (HMGF) is a desirable way for the automotive industry to produce complex metallic parts with poor formability, such as aluminum alloys. A simple hot gas forming method was developed to form aluminum alloy tubes using flame heating. An aluminum alloy tube was heated by a flame torch while the tube was rotated and compressed using a lathe machine and simultaneously pressurized with a constant air pressure. The effects of the internal pressure and axial feeding on expansion and wall thickness distribution were examined. The results showed that the proposed gas forming method was effective for forming aluminum alloy tubes. It was also indicated that axial feeding is a vital parameter to prevent reductions in wall thickness by supplying the material flow during the forming process.

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Numerical and experimental study of bursting prediction in tube hydroforming of Al 7020-T6

Cited by 14 publications

References 22 publications

Improvement of Die Corner Filling of Stepped Tubes Using Warm Hybrid Forming

Improvement of Die Corner Filling of Stepped Tubes Using Warm Hybrid Forming

Predictions of formability parameters in tube hydroforming process

Hot Gas Forming of Aluminum Alloy Tubes Using Flame Heating

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