Numerical study on electrohydraulic forming process to reduce the bouncing effect in electromagnetic forming

Flow forming is one of the cold forming process which is used for hollow symmetrical shapes. In this paper, the forward flow forming process is simulated using the finite element method and its results are compared with the experimental process. The variation of thickness of the sample is examined by the ultrasonic tests for the five locations of the tubes. To simulate the process, the ABAQUS explicit is used. The effects of flow forming variables such as the angle of rollers and rate of feeding of rollers, on the external variables such as internal diameter, thickness of tube and roller forces are considered. The study showed that the roller force and surface defects were reduced with low feeding rate and low rollers attack angles. Moreover, the sample internal diameter increased at low feeding rate and low rollers attack angles. The optimum variables for flow forming process were also obtained.

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Evaluation and optimization of effective parameters in electrohydraulic forming process

Journal of the Brazilian Society of Mechanical Sciences and Engineering ◽

10.1007/s40430-018-1449-1 ◽

2018 ◽

Vol 40 (11) ◽

Cited By ~ 4

Author(s):

Mehdi Zohoor ◽

Seyed Meysam Mousavi

Keyword(s):

Effective Parameters ◽

Forming Process ◽

Electrohydraulic Forming

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Enhancement of Formability of AA5052 Alloy Sheets by Electrohydraulic Forming Process

Journal of Materials Engineering and Performance ◽

10.1007/s11665-016-2446-0 ◽

2016 ◽

Vol 26 (1) ◽

pp. 439-452 ◽

Cited By ~ 10

Author(s):

Meraj Ahmed ◽

D. Ravi Kumar ◽

M. Nabi

Keyword(s):

Forming Process ◽

Electrohydraulic Forming

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Numerical Study on Effect of Using Elastic Pads in Flexible Forming Process

Transactions of the Korean Society of Mechanical Engineers A ◽

10.3795/ksme-a.2010.34.5.549 ◽

2010 ◽

Vol 34 (5) ◽

pp. 549-556 ◽

Cited By ~ 7

Author(s):

Seong-Chan Heo ◽

Young-Ho Seo ◽

Hak-Gon Noh ◽

Tae-Wan Ku ◽

Beom-Soo Kang

Keyword(s):

Numerical Study ◽

Forming Process ◽

Flexible Forming ◽

Flexible Forming Process

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Quadrilateral Shape Rib Forming by Roll Forming Process

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.878.296 ◽

2018 ◽

Vol 878 ◽

pp. 296-301

Author(s):

Dong Won Jung

Keyword(s):

Automotive Industry ◽

High Strength Steel ◽

Numerical Study ◽

Thickness Distribution ◽

High Strength ◽

Metal Sheet ◽

Product Performance ◽

Roll Forming ◽

Forming Process ◽

Roll Forming Process

The roll forming is one of the simplest manufacturing processes for meeting the continued needs of various industries. The roll forming is increasingly used in the automotive industry to form High Strength Steel (HSS) and Advanced High Strength Steel (AHSS) for making structural components. In order to reduce the thinning of the sheet product, traditionally the roll forming has been suggested instead of the stamping process. The increased product performance, higher quality, and the lowest cost with other advantages have made roll forming processes suitable to form any shapes in the sheets. In this numerical study, a Finite Element Method is applied to estimate the stress, strain and the thickness distribution in the metal sheet with quadrilateral shape, ribs formed by the 11 steps roll forming processes using a validated model. The metal sheet of size 1,000 × 662 × 1.6 mm taken from SGHS steel was used to form the quadrilateral shape ribs on it by the roll forming process. The simulation results of the 11 step roll forming show that the stress distribution was almost uniform and the strain distribution was concentrated on the ribs. The maximum thinning strain was observed in the order of 15.5 % in the middle rib region possibly due to the least degree of freedom of the material.

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