Tailor layered tube hydroforming for fabricating tubular parts with dissimilar thickness

Han, Sang-Il; Woo, Young Yun; Hwang, Taehyun; Oh, Ilyeong; Moon, Young Hoon

doi:10.1016/j.ijmachtools.2018.11.005

Cited by 45 publications

(10 citation statements)

References 28 publications

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“…The sensitivity analysis of thickness variations during tube bulging was studied [33], whereas a novel FLD diagram was developed for nonlinear loading paths under fixed and free conditions [34]. The tailor welded tubes were developed with various thicknesses components for hydroforming experimentation and also concluded that seam weld issues are resolved in tailor weld tube [35]. The wrinkling defects are analysed on magnesium alloy material under the axial feed condition and also predicted the variations in between deformation and axial feed by simulation [36].…”

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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Section: Introductionmentioning

confidence: 99%

Predictions of formability parameters in tube hydroforming process

Marlapalle¹,

Hingole²

2021

SN Appl. Sci.

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“…In general, conventional plastic forming processes, such as roll forming [3][4][5][6] and seamless tube manufacturing [7] methods, have been usually used to produce tubular parts. For relatively complex shaped products, hydroforming [8][9][10][11] and electromagnetic forming [12,13] have been used.…”

Section: Introductionmentioning

confidence: 99%

System Development for Diffusion Bonding of Multiple Unit Tubes to Produce Long Tubular Tungsten Heavy Alloys

Park¹,

Woo

Han

et al. 2020

Applied Sciences

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A diffusion bonding system to fabricate long tubular parts by joining of two- or more-unit tubes made of tungsten heavy alloys (THAs) is proposed and characterized in this study. The difficulty of powder processing of THA originates from the weak strength of the green compact and the high weight of the THA powders. The long tubular green compact is difficult to handle due to its weak structural integrity. Furthermore, gravity-induced slumping during liquid phase sintering induces dimensional distortion and degrades the mechanical performances. As a clue for solving these problems, the unit tubes are fabricated. However, the mass of green compacts for unit tubes is not sufficiently great as to cause problematic slumping; tubular unit tubes can be obtained without significant difficulty. Fabricated unit tubes are stacked in a furnace chamber and diffusion-bonded to produce a long tubular part having bond strength substantially equal to that of a monolithic tube. The proposed diffusion bonding system was well characterized and successfully applied to the industrial production line. The feasibility was also confirmed by investigating the bond quality, which can be assessed by metallographic microstructure and mechanical property.

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“…Sangwook Han et al. 16 (2019) studied high-performance tube fittings with different properties for hydroforming. Jae Hyun Ra et al.…”

Section: Introductionmentioning

confidence: 99%

External high-pressure forming of metal spiral tube of equal wall thickness

Shi

Deng

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part E:

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Positive displacement motors are widely used underground power tools in oil and gas extraction. In order to solve the problems of the short life of the conventional positive displacement motor and the difficulty of machining the constant wall positive displacement motor, this paper proposes a metal bush stator. Based on theoretical analysis and tensile experiment of 304 stainless steel, a finite element model of an external high-pressure forming equal-wall-thickness metal spiral tube was established. The finite element method is used to study the external high pressure forming spiral tube with equal wall thickness. According to the results of the numerical simulation, we choose the tube blank with the inner diameter of 88 mm×the wall thickness of 3 mm for the experiment of external high pressure forming spiral tube. The result of the experiment is that the inner and outer surfaces of the metal spiral tube are smooth, and the spiral tube has no wrinkles or cracks. The maximum gap between the spiral tube and the mold is 0.12 mm, and the inner surface of the spiral tube is close to the mold. The maximum gap are at the transition of convex arc and concave arc. The minimum wall thickness and the maximum wall thickness of the spiral tube are 2.6 mm and 3.205 mm, respectively. The quality of the spiral tube is better when the inner circumference length of the tube (D2)/the contour line circumference (D1) of the mold is 0.974. The experimental results are in good agreement with the numerical simulation results. We have designed an assembled mold, which can be removed smoothly after the experiment. The research results of this paper have important engineering significance for improving the working performance of positive displacement motors.

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Tailor layered tube hydroforming for fabricating tubular parts with dissimilar thickness

Cited by 45 publications

References 28 publications

Predictions of formability parameters in tube hydroforming process

Predictions of formability parameters in tube hydroforming process

System Development for Diffusion Bonding of Multiple Unit Tubes to Produce Long Tubular Tungsten Heavy Alloys

External high-pressure forming of metal spiral tube of equal wall thickness

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