Numerical investigation of controllable non-uniform deformation of tailor-welded blanks using heterogeneous pressure-carrying medium

Shu, Yi-quan; Xiang, Nan; Wang, Haoran; Yang, Meng-han; Wang, Pengyi; Huang, Tao; Guo, Junqing; Chen, Fuxiao

doi:10.1016/j.tws.2023.110663

Cited by 6 publications

(2 citation statements)

References 34 publications

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“…One approach to obtaining non-uniform pressure is using the heterogeneous pressure-carrying medium. Shu et al used heterogeneous rubber to deform the tailor-welded blank [27]. They glued two different rubbers as the flexible die.…”

Section: Introductionmentioning

confidence: 99%

Mechanism and experimental verification of non-uniform pressure in viscous pressure forming

Wang,

2024

Preprint

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The plastic deformation of the complex thin-walled components is not uniform. Applying a non-uniform load can decrease the thickness reduction and improve the thickness uniformity. In recent years, the application of non-uniform pressure to deform the sheet (such as magnetorheological pressure forming and viscous pressure forming) has attracted researchers’ attention. However, the characteristics of the non-uniform pressure have not been researched. Control of the non-uniform pressure in the forming process lacks theoretical support. In this study, the mechanism of the non-uniform pressure in the viscous pressure bulge test is investigated. The pressure-carrying medium, called viscous medium, is semi-solid and flowable. The inhomogeneous flow behavior of the medium produces non-uniform pressure when the maximum is at the bulged pole. The inhomogeneous deformation behavior of the medium produces non-uniform pressure when the minimum is at the bulged pole. The effects of flow and deformation are opposite. The non-uniform pressure function is derived, and the evolution of the pressure is presented. During forming, the viscosity of the medium increases with the pressure, so the effect of the flow behavior increases, and the pressure weight at the pole increases. Viscous pressure bulge tests are carried out to verify the theory. The gradient and evolution of the pressure can be controlled by the loading velocity and the property of the medium. The results provide theoretical guidance for the control of the pressure in viscous pressure forming, and the methodology is expected to analyze the non-uniform pressure in other flexible die forming processes.

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Section: Introductionmentioning

confidence: 99%

Mechanism and experimental verification of non-uniform pressure in viscous pressure forming

Wang,

2024

Preprint

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“…If the property of the rubber is heterogeneous, the transmitted pressure is not uniform. Shu et al used heterogeneous rubber to bulge the tailor-welded blank [29]. They glued two different rubbers as one flexible die.…”

Section: Introductionmentioning

confidence: 99%

Effect of the non-uniform pressure on the deformation and instability of the sheet in flexible-die bulge forming

Wang,

Wang

2024

Preprint

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In recent years, the application of non-uniform pressure in flexible-die forming, such as viscous pressure forming and magnetorheological pressure forming, has been utilized in manufacturing many thin-walled components. However, the non-uniform pressure is mainly applied to change the shape of the sheet. The effects of the non-uniform pressure on thickness reduction and fracture are still intricate. In this study, the mechanism of the non-uniform pressure to decrease thickness reduction and delay fracture instability in the bulge test is revealed. The non-uniform pressure changes the principal stresses, causing distinct deformation behaviors. There are two opposite effects on thickness reduction and fracture instability. If the pressure at the bulged pole decreases, the shape is more prolate, leading toa decreased average thickness and a decreased polar curvature. The thickness reduction tends to be severe, and the diffuse necking is easy to produce. If the pressure at the bulged pole increases, the shape is more oblate, leading to an increased strain gradient. The thickness reduction tends to be severe, and the localized necking is easy to produce. Characteristics of the pressure to decrease thickness reduction and delay instability are presented. Viscous pressure bulge tests are carried out. Experiment results of the shape, thickness uniformity, polar strain, and fracture verify the theory. The fracture strain increases by 5.6 % compared with the uniform pressure condition. This study proves that non-uniform pressure can promote sheet formability, indicating that non-uniform pressure has broad application prospects in sheet metal forming.

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Real-time and selective control of shell deformation based on dynamic and subregional pressure response of flexible dies under magnetic field

Xiang,

Wang,

Wang

et al. 2024

Int J Adv Manuf Technol

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Pressure-carrying properties of traditional exible materials can hardly be controlled during the process that they serve as pressure-carrying medium to form shell components. In this work, a forming method based on the subregional and dynamic pressure response of property-adjustable forming medium was proposed, aiming at achieving the exible control of shell deformation in different regions and stages.Elastic composites with iron particles selectively dispersed in pre-designed location, i.e., heterogeneous magneto-rheological elastomers (MREs), were fabricated and employed as the exible dies in the bulge tests of Al1060 sheet in the presence of external magnetic eld. Deformation behaviors of sheet metal were dynamically measured, and loading and stress conditions were numerically studied. The results showed that local shell deformation could be controlled in a nearly monotonic way by adjusting the distribution pattern and content (φ) of iron particles. In the case that heterogeneous MRE with φ = 0/30% was employed and magnetic eld with ux density (B) of 1950 Gs was applied, difference of bulge height and strain on both sides of the deformed shell increased by 6.5% and 16%, respectively. In the presence of magnetic eld with B = 1240Gs, difference of bulge height on both sides of the sheet metal increased by 9% compared with the condition that no magnetic eld is applied. But, the in uence of magnetic eld is not monotonous. Changed stress paths of sheet metal, which was induced by non-uniformly distributed and dynamically controllable pressure eld of heterogeneous MREs, was used to clarify the forming mechanism.

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Numerical investigation of controllable non-uniform deformation of tailor-welded blanks using heterogeneous pressure-carrying medium

Cited by 6 publications

References 34 publications

Mechanism and experimental verification of non-uniform pressure in viscous pressure forming

Mechanism and experimental verification of non-uniform pressure in viscous pressure forming

Effect of the non-uniform pressure on the deformation and instability of the sheet in flexible-die bulge forming

Real-time and selective control of shell deformation based on dynamic and subregional pressure response of flexible dies under magnetic field

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