The development of a novel forming limit diagram under nonlinear loading paths in tube hydroforming

Zhu, Haihui; Zhang, He; Lin, Yanli; Zheng, Kailun; Fan, Xiaobo; Yuan, Shijian

doi:10.1016/j.ijmecsci.2019.105392

Cited by 26 publications

(14 citation statements)

References 31 publications

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“…Note that the last item is not dε zθ 4Nσ zθ , because the term of 2Nσ 2 zθ is divided into Nσ 2 zθ + Nσ 2 θz when calculating the partial derivative zf zσ ij . The wall thickness at the pole point of the tube is low ( t0 R0 < 1 10 ), and thus the radial stress components can be ignored (σ r 0), resulting in the state of plane stress (Zhu et al, 2020). For plane stress σ r 0, Eq.…”

Section: Derivation Of Equivalent Stressmentioning

confidence: 99%

“…Figure 3 shows the geometry and stress of the infinitesimal element at the hydrobulging tube's pole. By analyzing this infinitesimal element, the expression of stress and strain components can be derived (Hwang and Lin, 2007;He et al, 2014a;He et al, 2014b;Zhu et al, 2020).…”

Section: Strain and Stress Analysis At The Pole Pointmentioning

confidence: 99%

“…One of the most popular methods to solve this problem is the tube hydro-bulging test (or hydraulic/tube bulge test). Numerous research studies have developed experimental devices to perform such tests (Fuchizawa et al, 1993;Sokolowski et al, 2000;Fllice et al, 2001;Aue-u-lan, 2007), and the hydro-bulging test has been effectively used to predict the forming limit (Zhu et al, 2020).…”

Section: Introductionmentioning

confidence: 99%

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Mechanics-Based Failure Model of Tube Hydro-Bulging Test

Liu

Dhawan

et al. 2022

Front. Mech. Eng.

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Tube hydroforming has been widely applied by the automotive sector to produce hollow parts. As a popular tube hydroforming test method, tube hydro-bulging needs an analytical failure model to analyze the formability of tubular materials. In the present work, a failure prediction model has been developed to predict the bulging height limit (BHL) of the hydro-bulging test. The model utilized Hill’s orthogonal anisotropic model to characterize the tube material, a geometry model to characterize the non-loading path and the M-K model to predict failure. Defects in multiple directions were taken into consideration. The developed model was applied on two tubes of different materials as case studies to verify its validity. It is shown that the developed model is capable of predicting the forming limit or determining the imperfection factor of tubular materials.

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Section: Derivation Of Equivalent Stressmentioning

confidence: 99%

Section: Strain and Stress Analysis At The Pole Pointmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Mechanics-Based Failure Model of Tube Hydro-Bulging Test

Liu

Dhawan

et al. 2022

Front. Mech. Eng.

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“…Hydroforming is a metal forming process whereby material deformation is achieved by the utilization of fluid pressure [5]. Forming limit diagrams play an important role in the design of this process [6,7] because they-apart from numerical modeling [8]-facilitate the selection of technological parameters for the process. As a result, it is possible to produce complex geometry parts that are difficult, if not impossible, to fabricate using other methods [9,10].…”

Section: Introductionmentioning

confidence: 99%

Theoretical and Experimental Study on the Effect of Selected Parameters in a New Method of Extrusion with a Movable Sleeve

Winiarski

2022

Materials

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This paper presents a new method for forming hollow flanged products. The method involves extrusion with the use of a sleeve moving in the opposite direction to that of the punch. A tube with a constant hole diameter and two different outside diameters, made of aluminum alloy EN AW 6060 was used as a material. Numerical calculations were performed using Deform 2D/3D. Experiments were conducted on the PYE 160SS hydraulic press equipped with a specially designed device in which the punch is driven by the press slide while the moveable sleeve is driven by two hydraulic servomotors. Both numerical simulations and experiments were conducted under cold forming conditions. The aim of this study was to determine the effect of selected parameters (flange diameter, height of the cavity in the moveable sleeve, and the chamfer angle between the regions with different outside diameters on the workpiece and in the moveable sleeve cavity) on the stability of the extrusion process. Results were then used to undertake detailed comparative analyses of underfill, flange heights, and flange flank inclination angles. Findings of the analyses served as a basis for drawing conclusions regarding the effect of the analyzed parameters on the investigated extrusion process.

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“…The FLC analysis demonstrates that the laser welded tube exhibits a better hydro-formability than that of the ERW tube under same input conditions [3,22,31,32]. 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].…”

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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The development of a novel forming limit diagram under nonlinear loading paths in tube hydroforming

Cited by 26 publications

References 31 publications

Mechanics-Based Failure Model of Tube Hydro-Bulging Test

Mechanics-Based Failure Model of Tube Hydro-Bulging Test

Theoretical and Experimental Study on the Effect of Selected Parameters in a New Method of Extrusion with a Movable Sleeve

Predictions of formability parameters in tube hydroforming process

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