Optimization of pressure paths in hydrodynamic deep drawing assisted by radial pressure with inward flowing liquid using a hybrid method

Hydrodynamic Deep Drawing (HDDRP), the combination of hydroforming and conventional deep drawing, accommodates the advantages of the two processes. A technique, called HDDRP with inward flowing liquid, has been introduced based on the idea of insertion of radial pressure around the blank rim. The radial pressure created on the blank edge, can increase the drawing ratio. Thus, increasing the radial pressure to an amount greater than the cavity pressure, and independent control of these pressures is the basic idea of this research for forming cylindrical parts. To perform the experiments, two independent pumps were used to provide the two pressures independently. The pressure supply system and the die set were designed in a way that provides simultaneous control of the pressures throughout the process. Then, the effects of radial pressure paths on thickness distribution of cylindrical St13 cups were investigated. In addition, a comparison between HDDRP and HDDRP with inward flowing liquid processes has been performed experimentally. Results indicated that using a higher radial pressure than the cavity pressure and controlling their values at any moment of the process enhances the thickness distribution of the formed part in all regions.

Download Full-text

Investigation of Forming Cylindrical Parts in a Modified Hydrodynamic Deep Drawing Assisted by Radial Pressure With Inward Flowing Liquid

Journal of Manufacturing Science and Engineering ◽

10.1115/1.4038512 ◽

2017 ◽

Vol 140 (3) ◽

Cited By ~ 4

Author(s):

Milad Sadegh Yazdi ◽

Mohammad Bakhshi-Jooybari ◽

Hamid Gorji ◽

Mohsen Shakeri ◽

Maziar Khademi

Keyword(s):

Deep Drawing ◽

Thickness Distribution ◽

Radial Pressure ◽

Chamber Pressure ◽

Drawing Ratio ◽

Forming Force ◽

Flowing Liquid ◽

Hydrodynamic Deep Drawing ◽

Study Results ◽

Formed Part

Among the sheet hydroforming processes, hydrodynamic deep drawing (HDD) process has been used to form complex shapes and can produce parts with high drawing ratio. Studies showed that radial pressure created on the edge of the sheet can decrease the drawing force and increase drawing ratio. Thus, increasing of radial pressure to an amount greater than chamber pressure, and independent control of these pressures, is the basic idea in this study. In this research, the effect of radial and chamber pressures on formability of St13 and pure copper sheets in the process of hydrodynamic deep drawing assisted by radial pressure (HDDRP) with inward flowing liquid is investigated. Giving that a significant portion of the maximum thinning of the formed part occurs in the beginning of the process, the pressure supply system used in the experimental tests was designed in a way, which provides simultaneous control of the radial and chamber pressures throughout the process. Thickness distribution, forming force, and tensile stresses are the parameters that were evaluated in this study. Results indicated that using a higher radial pressure than the chamber pressure and controlling their values in the initial stages of the process enhances the thickness distribution of the formed part in all regions. A comparison between the thickness distribution and maximum forming force of the formed parts by the HDDRP and HDDRP with inward flowing liquid methods showed that by applying the later method, parts with more uniform thickness distribution and less maximum thinning and forming force can be achieved.

Download Full-text

Investigation into hydrodynamic deep drawing assisted by radial pressure

Journal of Materials Processing Technology ◽

10.1016/j.jmatprotec.2004.01.053 ◽

2004 ◽

Vol 148 (1) ◽

pp. 119-131 ◽

Cited By ~ 38

Author(s):

Lihui Lang ◽

Joachim Danckert ◽

Karl Brian Nielsen

Keyword(s):

Deep Drawing ◽

Radial Pressure ◽

Hydrodynamic Deep Drawing

Download Full-text

Process analysis of hydrodynamic deep drawing of cone cups assisted by radial pressure

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1177/0954405415612325 ◽

2015 ◽

Vol 231 (10) ◽

pp. 1793-1802 ◽

Cited By ~ 7

Author(s):

Alireza Jalil ◽

Mohammad Hoseinpour Gollo ◽

SM Hossein Seyedkashi

Keyword(s):

Deep Drawing ◽

Critical Pressure ◽

Process Analysis ◽

Fluid Pressure ◽

Radial Pressure ◽

Strain Hardening Exponent ◽

Geometrical Parameters ◽

Drawing Ratio ◽

Hydrodynamic Deep Drawing ◽

Rupture Pressure

Forming of flat sheets into shell conical parts is a complex manufacturing process. Hydrodynamic deep drawing process assisted by radial pressure is a new hydroforming technology in which fluid pressure is applied to the peripheral edge of the sheet in addition to the sheet surface. This technique results in higher drawing ratio and dimensional accuracy, better surface quality, and ability of forming more complex geometries. In this research, a new theoretical model is developed to predict the critical rupture pressure in production of cone cups. In this analysis, Barlat–Lian yield criterion is utilized and tensile instability is considered based on the maximum load applied on the sheet. The proposed model is then validated by a series of experiments. The theoretical predictions are in good agreement with the experimental results. The effects of geometrical parameters and material properties on critical rupture pressure are also studied. The critical pressure is increased with increase in the height ratio, strain hardening exponent, and anisotropy. Higher punch nose radius expands the safe zone. It is shown that the critical pressure decreases for drawing ratios higher than 4.

Download Full-text

Study of Al/St laminated sheet and constituent layers in radial pressure-assisted hydrodynamic deep drawing

Materials and Manufacturing Processes ◽

10.1080/10426914.2015.1127947 ◽

2016 ◽

Vol 32 (1) ◽

pp. 54-61 ◽

Cited By ~ 15

Author(s):

A. Hashemi ◽

M. Hoseinpour Gollo ◽

S. M. H. Seyedkashi

Keyword(s):

Deep Drawing ◽

Radial Pressure ◽

Hydrodynamic Deep Drawing

Download Full-text

Adaptive hybrid optimization of hydrodynamic deep drawing with radial pressure process by combination of parametric design and simulated annealing techniques

Proceedings of the Institution of Mechanical Engineers Part C Journal of Mechanical Engineering Science ◽

10.1177/0954406216669176 ◽

2016 ◽

Vol 231 (24) ◽

pp. 4564-4575 ◽

Cited By ~ 1

Author(s):

Abbas Hashemi ◽

Mohammad Hoseinpour Gollo ◽

SM Hossein Seyedkashi ◽

Ali Pourkamali Anaraki

Keyword(s):

Finite Element ◽

Simulated Annealing ◽

Regression Model ◽

Deep Drawing ◽

Parametric Design ◽

Radial Pressure ◽

Design Language ◽

Hydrodynamic Deep Drawing ◽

Definition Of ◽

Ansys Parametric Design Language

An adaptive hybrid simulated annealing technique with ANSYS parametric design language is developed to optimize hydrodynamic deep drawing assisted by radial pressure process. This work aims to determine an optimal pressure path by redefinition of simulated annealing parameters and creating an adaptive finite element code using ANSYS parametric design language for any cylindrical, conical, and conical–cylindrical cups. The simulated annealing algorithm is developed adaptively with respect to hydrodynamic deep drawing with radial pressure process to link with ANSYS parametric design language code using a script in MATLAB. Parametric definition of process parameters enables the optimization algorithm to change the finite element model configuration in each iteration. Defective product is detected by definition of two failure criteria based on thinning and wrinkling occurrence during the optimization process. The proposed optimization method is employed in fractional factorial design of experiment to investigate the effective parameters on final product quality. Also, a regression model is derived to predict the final product quality based on the maximum thinning percentage under the optimal pressure path. Reliability of the optimization procedure and regression model is validated by experiments.

Download Full-text