Determination of the loading path for tube hydroforming process of a copper joint using a fuzzy controller

2008 ◽  
Vol 43 (1-2) ◽  
pp. 1-10 ◽  
Author(s):  
Farough Mohammadi ◽  
Mahmoud Mosavi Mashadi
Keyword(s):  
Fuzzy Controller ◽  
Tube Hydroforming ◽  
Loading Path ◽  
Hydroforming Process

scholarly journals Movable Die and Loading Path Design in Tube Hydroforming of Irregular Bellows

Metals ◽  
2020 ◽  
Vol 10 (11) ◽  
pp. 1518
Author(s):  
Yeong-Maw Hwang ◽  
Yau-Jiun Tsai
Keyword(s):  
Tube Hydroforming ◽  
Simulation Software ◽  
Die Design ◽  
Loading Path ◽  
Feeding Types ◽  
Element Simulation ◽  
Hydroforming Process ◽  
Formed Product ◽  
Loading Path Design ◽  
Deform 3D

Manufacturing of irregular bellows with small corner radii and sharp angles is a challenge in tube hydroforming processes. Design of movable dies with an appropriate loading path is an alternative solution to obtain products with required geometrical and dimensional specifications. In this paper, a tube hydroforming process using a novel movable die design is developed to decrease the internal pressure and the maximal thinning ratio in the formed product. Two kinds of feeding types are proposed to make the maximal thinning ratio in the formed bellows as small as possible. A finite element simulation software “DEFORM 3D” is used to analyze the plastic deformation of the tube within the die cavity using the proposed movable die design. Forming windows for sound products using different feeding types are also investigated. Finally, tube hydroforming experiments of irregular bellows are conducted and experimental thickness distributions of the products are compared with the simulation results to validate the analytical modeling with the proposed movable die concept.

A comprehensive damage criterion in tube hydroforming

2020 ◽  
pp. 095440542096296
Author(s):  
Reza Pourhamid ◽  
Ali Shirazi
Keyword(s):  
Damage Model ◽  
Tube Hydroforming ◽  
Material Model ◽  
Vital Role ◽  
Numerical Results ◽  
Loading Path ◽  
Ring Compression Test ◽  
Damage Criterion ◽  
Ring Compression ◽  
Hydroforming Process

In the present study, the Johnson-Cook damage model is proposed as a comprehensive damage criterion to predict all types of probable failures in tube hydroforming process. Also, the Johnson-Cook material model is used to predict the profile of hydroformed tubes and their dimensions. The validity of numerical results was verified using experimental results obtained in this study. Moreover, because of the importance of friction force in this process, existing between the tube and die, the friction coefficient is determined using the ring compression test, separately. The comparison of experimental and numerical results shows that Johnson-Cook damage model can predict all of the possible failures in tube hydroforming process correctly, both in terms of location and loading conditions. And this model does not predict any failure if, the tube is hydroformed perfectly. Additionally, it was cleared that the Johnson-Cook material model is a proper model to predict the profile of hydroformed tubes with remarkable accuracy. Also, it was found that the loading path and creation of a proper wrinkling have a determinative and vital role in the prosperity of the process.

Numerical analysis in a beverage can utilizing tube hydroforming process

2019 ◽  
Vol 28 (6) ◽  
pp. 77-83
Author(s):  
Jorge Carlos León Anaya ◽  
José Antonio Juanico Loran ◽  
Juan Carlos Cisneros Ortega
Keyword(s):  
Mechanical Properties ◽  
Numerical Analysis ◽  
Metal Forming ◽  
Tube Hydroforming ◽  
Forming Process ◽  
Aluminum Tube ◽  
Plastic Deformation Process ◽  
Metal Forming Process ◽  
Hydroforming Process

Numerical analysis for Tube Hydroforming (THF) was developed in this work to predict the behavior of extruded aluminum tube in a forming die for beverage can applications. THF is a metal forming process dependent of three parameters: friction between the tube and the die, internal pressure, and material properties of the tube. Strain hardening is a governing phenomenon that occurs in the plastic deformation process of metals. Hollomon’s equation offers a mathematical description of the metal behavior in the plastic zone. For a proper simulation, experimental determination of the mechanical properties of aluminum 6061-T5 were conducted and test specimens where obtained directly from the aluminum tube. Experimental data were necessary because no sufficient data of the mechanical properties of the tube were available in the literature. Numerical simulations of THF were performed, and the results were compared with analytical results for validation purposes with less than 10% of error.

A New Method for Determination of the Pre-Form Shapes and Their Corresponding Pressures in Tube-Hydroforming Process of SUS 304 in a Square Die

2011 ◽  
Author(s):  
S. A. Tabatabaei ◽  
M. Shariat Panahi ◽  
S. M. Tabatabaei ◽  
M. Mosavi Mashhadi
Keyword(s):  
Neural Network ◽  
Tube Hydroforming ◽  
Production Equipment ◽  
Geometrical Shape ◽  
Hydroforming Process ◽  
Form Design ◽  
Trained Neural Network ◽  
Minimum Work ◽  
Tool Cost

The pre-form design in hydroforming process plays a key role in improving product quality, such as defect-free property and proper final product. This approach, however, leads not only to the increase of significant tool cost but also to the extended down-time of the production equipment. It is thus necessary to reduce time and man power through an effective method of pre-form design. In this paper, the equi-potential lines designed in the electric field are introduced to find an appropriate pre-form shape. The equi-potential lines generated between two conductors of different voltages show similar trends for minimum work paths between the undeformed shape and the deformed shape. Based on this similarity, the equi-potential lines obtained by arrangement of the initial and final shapes are utilized for the design of the pre-form, and then the finite element simulations are done for finding the forming pressure of each pre-form shape. Finally, the pre-form and its corresponding forming pressure with other parameters are used for training an artificial neural network. This trained neural network can be used for estimating the proper pre-form shape and forming pressure for a SUS304 tube inside an square die or other configurations of die (Geometrical shape) and tube (Diameter and thickness).

Automatic Approach on Derivation of Loading Path Using Adaptive Finite Element Analysis Simulation Method

2007 ◽  
Vol 340-341 ◽  
pp. 359-364
Author(s):  
Seong Chan Heo ◽  
Jeong Kim ◽  
Beom Soo Kang
Keyword(s):  
Tube Hydroforming ◽  
Process Condition ◽  
Simulation Method ◽  
Major Effect ◽  
Loading Path ◽  
Forming Limit ◽  
Adaptive Finite Element ◽  
Element Analysis ◽  
Finite Element Analysis Simulation

Loading path is one of the most influential parameter in tube hydroforming(THF) process. Load history has a major effect on failures such as buckling, necking, bursting, and so on. Because loading conditions that consist of axial feeding and internal pressure are imposed simultaneously. Therefore suitable loading path should be determined to prevent onset of failures i.e. bursting on final products. This paper deals with the procedure on determination of the loading path in order to ensure the robustness of the final products after the THF. In order to verify the availability and feasibility of the proposed methodology a subframe model of engine cradle module in automotive is implemented. In this study, thinning ratio and forming limit stress diagram is used to demonstrate the improvement of the finished product. The result shows that the developed algorithm has successfully promoted the effectiveness and feasibility in the THF. Consequently, it is shown that the automatic approach on the determination of loading condition which is proposed in this paper will provide a valuable method to satisfy the increasing practical demands for designing process condition in THF.

Study on Product Design and Process Simulation of Hydroformed Automobile Framework

2010 ◽  
Vol 102-104 ◽  
pp. 210-213
Author(s):  
Lin Zhou ◽  
Xiao Min Cheng
Keyword(s):  
Numerical Simulation ◽  
Process Simulation ◽  
Tube Hydroforming ◽  
Shell Element ◽  
Loading Path ◽  
Pressure Loading ◽  
Vehicle Performance ◽  
Simulation Based ◽  
Hydroforming Process ◽  
Element Theory

To achieve smaller weight, stronger strength and higher stiffness, tube hydroforming is widely used in the industry. The front beam is analysed the front beam part is redesigned based on the technics, and automotive structural lightweight and integration are achieved under the precondition of ensuring vehicle performance and security. Then, the hydroforming process of front beam is analyzed by numerical simulation based upon the elastic-plastic finite element method, Belytschko-Tsay shell element theory and dynamic explicit solution, the internal pressure loading path as the main hydroforming process parameters is discussed in detail. The present analysis provide basis for its applications.

Sign in / Sign up

Export Citation Format

Share Document