Optimum design of preform geometry and forming pressure in tube hydroforming using the equi-potential lines method

Tabatabaei, Seyed Ahmad; Panahi, Masoud Shariat; Mashhadi, Mahmoud Mosavi; Tabatabee, S. M.; Aghajanzadeh, Mohammad

doi:10.1007/s00170-013-5235-z

Cited by 15 publications

(3 citation statements)

References 13 publications

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“…But an inappropriate pre-form shape will lead to serious local thinning at the carrying region, which will weaken the carrying performance of the cross member. In order to design a well-pre-formed shape before hydro-forming, response surface methodology, which is a collection of statistical methods for designing experiments, developing models, evaluating the effects of factors, and searching for the optimal solution of the factors, has been carried out [19]. The response values are obtained by numerical simulation.…”

Section: Pre-form Shape Design By Response Surface Methodologymentioning

confidence: 99%

“…For the hydro-forming process of aluminum alloy components with a variable sectional profile, the preforming process is very important, because an appropriate pre-form shape can both avoid a flash defect occurring in the die closing process and deform uniformly during the hydro-forming process without wrinkles and fracture defects [18][19][20].…”

Section: Introductionmentioning

confidence: 99%

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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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Section: Pre-form Shape Design By Response Surface Methodologymentioning

confidence: 99%

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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“…Then the preform is clamped by the die and calibrated by the high internal pressure in the subsequent calibration process. It is also an effective method to improve the uniformity of wall thickness [15]. Third, it is also an effective method to improve the wall thickness distribution by controlling the contact sequence of the die and the tube blank in the circumferential direction.…”

Section: Introductionmentioning

confidence: 99%

Thickness Improvement and Calibration Pressure Reduction of Stepped Tubular Components Using Axial Hydro-pressing Method

Han

Zhuang

2021

Preprint

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A new tube axial hydro-pressing method was proposed to solve the problems of high forming pressure and severely uneven wall thickness distribution of traditional tube hydroforming methods to form stepped tubular components. The forming pressure of the traditional hydroforming and the tube axial hydro-pressing method is studied theoretically, the mechanical model of the fillet area is established, and the forming pressure calculation formula is given. Based on this, an investigation of the tube axial hydro-pressing method is carried out by numerical simulation and experimental methods, and compared with the traditional tube hydroforming method. The key to the tube axial hydro-pressing method is to precisely control the relationship between the protrusion height and the axial feed, which is achieved by precisely controlling the feeding pressure and the axial displacement. Therefore, the constant pressure device in the experiment was used to eliminate the influence of the pressure rise caused by the volume compression on its cooperation relationship, to achieve accurate control of the loading path, eliminate wrinkles and flash defects. A qualified workpiece is successfully manufactured when the internal pressure is 18.0 MPa and the feed on each side is 15.0 mm. The forming pressure is reduced by 88.0%, and the feed is increased by 6.5%, which reduces the wall thickness reduction by 9.0%. The wall thickness difference of the workpiece can be controlled within 7.0%. The tube axial hydro-pressing method is suitable for forming stepped tubular components, which can achieve more replenishment at lower pressures, thereby effectively improving the uniformity of wall thickness and significantly reducing the forming pressure.

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