Pre-form design for hydro-forming of aluminum alloy automotive cross members

Cai, Yang; Wang, X. S.; Yuan, Shijian

doi:10.1007/s00170-015-8160-5

Cited by 11 publications

(3 citation statements)

References 16 publications

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“…In addition, the maximum hydraulic pressure was decreased via hydroforming of doublelayer sheets. This method reduced the drawing force for large sheet parts and meets the requirement of energy conservation [58][59][60].…”

Section: Aluminum Alloy Behavior During Hydroforming Processmentioning

confidence: 99%

Aluminum Alloys Behavior during Forming

Ramulu¹

2020

Aluminium Alloys and Composites

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Industrial revolution toward weight reduction and fuel efficiency of the automotive and aerospace vehicles is the major concern to replace heavy metals with light weight metals without affecting much strength. For this, aluminum alloys are the major contributors to those industries. Moreover, aluminum alloys are majorly categorized as 1xxx, 2xxx, 3xxx, 4xxx, 5xxx, 6xxx, 7xxx, and 8xxx based on major alloying elements. Among all, 2xxx, 5xxx, 6xxx, and 7xxx are having majority of applications in the abovementioned industries. For manufacturing any engineering deformable components, forming characteristics are must. Forming behavior of aluminum alloys has been evaluated through different processes including deep drawing, stretching, incremental forming, bending, hydro forming etc., under different process conditions (cold, warm, and hot conditions) and process parameters. Each process has its own process feasibility to evaluate the formability without any forming defects in products. The present chapter discusses a few important processes and their parameter effect on the aluminum alloys through the experimentations and simulation works.

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Section: Aluminum Alloy Behavior During Hydroforming Processmentioning

confidence: 99%

Aluminum Alloys Behavior during Forming

Ramulu¹

2020

Aluminium Alloys and Composites

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“…The shapes of the formed parts are generally complex, and thin-walled tubes exhibit significant plastic anisotropy [ 8 , 9 , 10 ], making it difficult to accurately predict the reasonable loading paths through theoretical analysis and experiments [ 11 ]. Therefore, FE simulation is usually used to determine and optimize process parameters before experiments [ 12 ]. However, the accuracy of FE simulation largely depends on the accuracy of the constitutive model used to describe the material properties including the plastic flow, yielding, and hardening characteristics [ 13 ].…”

Section: Introductionmentioning

confidence: 99%

Identification of Anisotropic Coefficients in the Non-Principal Axis Directions of Tubular Materials Using Hole Bulging Test

Lin

Wang

et al. 2023

Materials

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We propose an experimental method to identify anisotropic coefficients in non-principal axis directions of thin-walled tubes. The method involves extracting specimens from the parent tubes and machining a hole in the axial center. The specimens are then inserted into a tube without a hole. The inner diameter of the specimen is theoretically equal to the outer diameter of the inner tube. The double-layer tube undergoes free bulging under internal pressure in our self-developed experimental equipment, with the hole on the specimen expanding simultaneously. The stress states around the hole are uniaxial, and the hole deformation can reflect the anisotropic plastic flow characteristics of the tube. Furthermore, based on the information obtained from the proposed experimental method, a hybrid numerical–experimental method was used to identify the anisotropic coefficients of tubes. Through FE simulations, the relationships between the thickness, stress, and strain states around the hole, the hole shape, and anisotropic coefficients of non-principal axis directions are revealed, and the factors that affect the hole deformation are analyzed. Finally, the hole bulging experiments and FE simulations of AA6061-O extruded tube were conducted, and modeled with Hill48 and calibrated by uniaxial tensile and hoop tensile tests. Its in-plane anisotropy coefficients in any direction are given for the first time which first increase and then decrease from 0° to 90°, reaching a maximum of 1.13 in 60° and a minimum of 0.69 in 0°. This work can provide the key experimental data for establishing an accurate anisotropic plastic constitutive model of thin-walled tubes.

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“…Aluminum alloy has played an important role in lightening automobiles [ 1 , 2 , 3 ], with hydroformed aluminum tubes making it possible to create lightweight parts with spatial structures and complex sections [ 2 , 4 , 5 , 6 ] that can replace steel in high-end cars, and achieve energy savings and emission reductions. The first aluminum alloy rear axle subframe made by hydroforming was used in the 5-series BMW(Bayerische Motoren Werke), with its total weight of only 11.5 kg achieving a significant weight reduction when compared to steel [ 7 ].…”

Section: Introductionmentioning

confidence: 99%

Surface Roughening Behavior of 6063 Aluminum Alloy during Bulging by Spun Tubes

2017

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Severe surface roughening during the hydroforming of aluminum alloy parts can produce surface defects that severely restrict their application in the automobile and aerospace industry. To understand the relation between strain, grain size and surface roughness under biaxial stress conditions, hydro-bulging tests of aluminum alloy tubes were carried out, and the tubes with different grain sizes were prepared by a spinning and annealing process. The surface roughness was measured by a laser scanning confocal microscope to evaluate the surface roughening macroscopical behavior, and the corresponding microstructures were observed using electron back-scattered diffraction (EBSD) to reveal the roughening microscopic behavior. The results obtained show that the surface roughness increased with both strain and grain size under biaxial stress. No surface defects were observed on the surface when the grain size was less than 105 μm if the strain was less than 18%, or when the grain size was between 130 and 175 μm if the strain was less than 15.88% and 7.15%, respectively. The surface roughening microscopic behavior was identified as an inhomogeneous grain size distribution, which became more pronounced with increasing grain size and resulted in greater local deformation. Concentrated grain orientation also results in severe inhomogeneous deformation during plastics deformation, and serious surface roughening.

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Pre-form design for hydro-forming of aluminum alloy automotive cross members

Cited by 11 publications

References 16 publications

Aluminum Alloys Behavior during Forming

Aluminum Alloys Behavior during Forming

Identification of Anisotropic Coefficients in the Non-Principal Axis Directions of Tubular Materials Using Hole Bulging Test

Surface Roughening Behavior of 6063 Aluminum Alloy during Bulging by Spun Tubes

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