The effect of the key process parameters in the innovative hydroforming on the formed parts

Lang, Lihui; Li, Tao; Zhou, Xiaofeng; Danckert, Joachim; Nielsen, Kjeld

doi:10.1016/j.jmatprotec.2006.11.196

Cited by 17 publications

(5 citation statements)

References 12 publications

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“…As well, with a material of a higher anisotropy ratio and strain hardening exponent, higher cup depth can be achieved. Lang et al [38] were investigated numerically and experimentally the influence of hydroforming process parameters on the forming quality, as well as the formability improvement. They focused on the roundness and surface roughness parameters of the formed aluminum alloys parts.…”

Section: Introductionmentioning

confidence: 99%

Effect of Hydroforming Drawing Cups on Thickness Variation and Surface Roughness

El–Adl

Abouelatta

Samuel

et al. 2022

JERA

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Recently, hydroforming was developed to address the emerging problems encountered by the conventional rigid tool-based deep drawing process. Hydroforming is a specialized type of die forming process, that uses a rigid die while the pressure provided by the liquid acts as a punch to shape the sheet metal. The current paper is directed to study the hydroforming process numerically and experimentally as a means for shaping aluminum alloy sheets based on the quality of product thickness variation and surface roughness. Moreover, it offered a comparative investigation of the experimental and numerical findings of this process. Therefore, thickness variation has been calculated numerically by designing a numerical model using Marc software which fits in large deformation simulation. On the other hand, thickness variation and surface roughness were measured experimentally along drawn cups and compared with the numerical results. The numerical results of thickness variation are matched with the experimental results. Furthermore, surface roughness was measured and compared before and after drawing at five regions. Since there is no contact between the upper side of a cup and any metallic parts, surface roughness depends only on the effect of plastic strain and was found to be increased in all regions.

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Section: Introductionmentioning

confidence: 99%

Effect of Hydroforming Drawing Cups on Thickness Variation and Surface Roughness

El–Adl

Abouelatta

Samuel

et al. 2022

JERA

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“…They also studied the impact of radial pressure on drawing ratio and realized that for forming a cup with a drawing ratio higher than 2.5, a radial pressure higher than the die cavity pressure must be applied. Lang et al [12] studied the effect of pre-bulging pressure and height in hydromechanical deep drawing with uniform pressure into the blank experimentally. They found that the roundness of the cup would be better when the drawing ratio is higher.…”

Section: Introductionmentioning

confidence: 99%

Analysis of the effects of tool and process parameters in hydrodynamic deep drawing assisted by radial pressure

Salahshoor

Gorji

Bakhshi-Jooybari

2019

J Braz. Soc. Mech. Sci. Eng.

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Among the various techniques of sheet hydroforming, hydrodynamic deep drawing assisted by radial pressure (HDDRP) has showed good results to shape parts with uniform thickness distribution and high drawing ratio. In this paper, improving formability of the parts in HDDRP is taken into consideration and the effects of some geometrical parameters such as the die profile radius and the gap between the die and the blank holder, and some process parameters such as pressure path and friction coefficient are investigated on thickness distribution of cylindrical cups and punch force. The pressure path has a great effect on the formability. The results showed that increasing the maximum pressure reduces part thinning in the critical regions. Increasing the pressure above a certain value does not have a significant effect on the part forming, but it increases the punch force. The most appropriate pressure path for forming the part studied in this paper is 27 MPa. Furthermore, thinning of the part and maximum punch force decreases by decreasing the friction between the sheet and blank holder. Moreover, increasing the friction coefficient between the punch and sheet to a certain value (0.2) improves forming condition that results in decreasing thinning of the part. Increasing the friction coefficient more than this value does not have a significant effect on forming the part. Friction between the punch and the sheet does not affect the maximum punch force. The results also illustrated that by increasing the gap between the blank holder and the die to 1.2 mm which is more than the thickness of the sheet, thickness reduction of the part and maximum punch force decreases. Increasing the gap above this value does not have a significant effect on ease of sheet flow and improving part formability.

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“…The parameters of SHF process could be optimized through the theoretical analysis or simulation for making the products with simple geometry such as circle and square cups. 9,10 However, they are still to be investigated for making the products with very complex geometry.…”

Section: Introductionmentioning

confidence: 99%

Development of sheet hydroforming for making an automobile fuel tank

Wang

Fan

et al. 2015

Proceedings of the Institution of Mechanical Engineers, Part B:

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This article aims at the development of sheet hydroforming for making an aluminum automobile fuel tank which is originally made by steel. Finite element model, including punch, blank, blank holder, binder and die cavity, is established in the first place. A commercial code LS-DYNA is used to simulate the forming process. Simulations are performed to investigate the design parameters, such as pressure, holding force, punch feeding and geometry of blank trimming, which are used for the experiment of prototyping. The prototypes of aluminum fuel tank are then fabricated and used to validate the simulation results. The experimental results show that simulations successfully predict the geometry, size, thickness distributions and location of maximum thinning ratio of aluminum fuel tank using sheet hydroforming.

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The effect of the key process parameters in the innovative hydroforming on the formed parts

Cited by 17 publications

References 12 publications

Effect of Hydroforming Drawing Cups on Thickness Variation and Surface Roughness

Effect of Hydroforming Drawing Cups on Thickness Variation and Surface Roughness

Analysis of the effects of tool and process parameters in hydrodynamic deep drawing assisted by radial pressure

Development of sheet hydroforming for making an automobile fuel tank

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