Scalability of conventional tube hydroforming processes from macro to micro/meso

2017 ◽  
Vol 232 (12) ◽  
pp. 2164-2177 ◽  
Author(s):  
James Lowrie ◽  
Gracious Ngaile
Keyword(s):  
Tube Hydroforming ◽  
Small Scale ◽  
Forming Process ◽  
Element Analysis ◽  
Aspect Ratios ◽  
Small Complex ◽  
Metal Forming Process ◽  
Hydroforming Process ◽  
Increasing Demand ◽  
Complex Parts

Due to the increasing demand for small, complex parts, researchers are putting a great deal of effort into applying the metal forming process to the micro and meso world. However, the tube hydroforming process is yet to be fully realized on this small scale because of the difficulties which arise in scaling the conventional tooling to the microscale. This article discusses the difficulties that arise as a result of simply shrinking the traditional hydroforming tools to the microscale. A simple mathematical model is then proposed as a way to help designers determine the limits of the conventional punch with a tapered nose commonly used in tube hydroforming. The model is then validated by performing a finite element analysis of the punch, and the results of the model are discussed in relation to the scaling concepts posed at the beginning of this article. It is determined that as the punch shrinks down, the stresses on the punch rise significantly as a result of changing aspect ratios of the workpiece and the inability to accurately machine very small holes through the punch body. A nonconventional tube hydroforming method may therefore be required to perform micro-tube hydroforming operations, especially on harder materials.

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.

Real-Time Friction Error Compensation in Tube Hydroforming Process Control

2011 ◽  
Vol 133 (6) ◽  
Author(s):  
Gracious Ngaile ◽  
Chen Yang ◽  
Obadiah Kilonzo
Keyword(s):  
Process Control ◽  
Real Time ◽  
Error Compensation ◽  
Tube Hydroforming ◽  
Loading Path ◽  
Forming Process ◽  
Loading Paths ◽  
Proposed Model ◽  
Metal Forming Process ◽  
Hydroforming Process

Tube hydroforming (THF) is a metal-forming process that uses a pressurized fluid in place of a hard tool to plastically deform a given tube into a desired shape. In addition to the internal pressure, the tube material is fed axially toward the die cavity. One of the challenges in THF is the nonlinear and varying friction conditions at the tube-tool interface, which make it difficult to establish accurate loading paths (pressure versus feed) for THF. A THF process control model that can compensate for the loading path deviation due to frictional errors in tube hydroforming is proposed. In the proposed model, an algorithm and a software platform have been developed such that the sensed forming load from a THF machine is mapped to a database containing a set of loading paths that correspond to different friction conditions for a specific part. A real-time friction error compensation is then carried out by readjusting the loading path as the THF process progresses. This scheme reduces part failures that would normally occur due to variability in friction conditions. The implementation and experimental verification of the proposed model is discussed.

Real Time Friction Error Compensation in Tube Hydroforming Process Control

2011 ◽  
Author(s):  
Gracious Ngaile ◽  
Obadiah Kilonzo ◽  
Chen Yang
Keyword(s):  
Process Control ◽  
Real Time ◽  
Error Compensation ◽  
Tube Hydroforming ◽  
Loading Path ◽  
Forming Process ◽  
Loading Paths ◽  
Proposed Model ◽  
Metal Forming Process ◽  
Hydroforming Process

Tube Hydroforming (THF) is a metal-forming process that uses a pressurized fluid in place of a hard tool to plastically deform a given tube into a desired shape. In addition to the internal pressure, the tube material is fed axially toward the die cavity. One of the challenges in THF is the nonlinear and varying friction conditions at the tube-tool interface, which make it difficult to establish accurate loading paths (pressure vs feed) for THF. A THF process control model that can compensate for the loading path deviation due to frictional errors in tube hydroforming is proposed. In the proposed model, an algorithm and a software platform have been developed such that the sensed forming load from a THF machine is mapped to a database containing a set of loading paths that correspond to different friction conditions for a specific part. A real-time friction error compensation is then carried out by readjusting the loading path as the THF process progresses. This scheme reduces part failures that would normally occur due to variability in friction conditions. The implementation and experimental verification of the proposed model is discussed.

Advanced In-Process Control System for Sheet Stamping and Tube Hydroforming Processes

2014 ◽  
Vol 622-623 ◽  
pp. 3-14 ◽  
Author(s):  
Kenichi Manabe
Keyword(s):  
Process Control ◽  
Metal Forming ◽  
Tube Hydroforming ◽  
Essential Element ◽  
Forming Limit ◽  
Forming Process ◽  
Intelligent Technique ◽  
Sheet Stamping ◽  
Adaptive Process Control ◽  
Metal Forming Process

A sophisticated servo press with the digital control has been developed and attracted attention in recent years. By utilizing its high function in-process, servo presses have a potential to enhance the forming limit and to improve quality and accuracy of product not only in sheet stamping but also in tube hydroforming processes. On the other hand, in-process control and adaptive process control technologies in metal forming processes using intelligent technique and soft computing have been investigated and developed previously. Nowadays we are in a good environment to realize further advanced adaptive in-process control in metal forming process. To further advance this technology, sensing system is essential element and it should be applied to feedback control optimally in their forming operation. This paper describes the current situation on advanced intelligent process control technology for sheet stamping and tube hydroforming processes on the basis of the research results by the author.

Reliability Analysis of the Tube Hydroforming Process Based on Forming Limit Diagram

2005 ◽  
Vol 128 (3) ◽  
pp. 402-407 ◽  
Author(s):  
Bing Li ◽  
Don R. Metzger ◽  
Tim J. Nye
Keyword(s):  
Automotive Industry ◽  
Metal Forming ◽  
Tube Hydroforming ◽  
Forming Limit Diagram ◽  
Probability Of Failure ◽  
Alternative Methods ◽  
Forming Limit ◽  
Forming Process ◽  
Hydroforming Process ◽  
Free Bulging

Tube hydroforming is an attractive manufacturing process in the automotive industry because it has several advantages over alternative methods. In order to determine the reliability of the process, a new method to assess the probability of failure is proposed in this paper. The method is based on the reliability theory and the forming limit diagram, which has been extensively used in metal forming as the criteria of formability. From the forming limit band in the forming limit diagram, the reliability of the forming process can be evaluated. A tube hydroforming process of free bulging is then introduced as an example to illustrate the approach. The results show this technique to be an innovative approach to avoid failure during tube hydroforming.

Mechanical Characterization of Thin SOFC Electrolytes With Honeycomb Support

2013 ◽  
Vol 10 (1) ◽  
Author(s):  
Ryan B. Berke ◽  
Mark E. Walter
Keyword(s):  
Effective Properties ◽  
Mesoscale Model ◽  
Honeycomb Structure ◽  
Small Scale ◽  
Element Analysis ◽  
Aspect Ratios ◽  
Electrolyte Membranes ◽  
Point Bend ◽  
Representative Area

Planar solid oxide fuel cells are made up of repeating sequences of electrolytes, electrodes, seals, and current collectors. The electrolyte should be as thin as possible for optimal electrochemical efficiency; however, for electrolyte-supported cells, the thin electrolytes are susceptible to damage during production, assembly, and operation. To produce cells that are sufficiently mechanically robust, electrolytes can be made having a cosintered honeycomb structure that supports thin, electrochemically efficient electrolyte membranes. Use of finite element analysis is desirable to mechanically characterize such electrolytes. To maintain reasonable numbers of elements and element aspect ratios, it is not possible to simultaneously model the small-scale details together with the overall membrane response. A two-scale approach is devised: the smaller mesoscale analyzes a representative area of the electrolyte, while the larger macroscale examines the electrolyte as a whole. Elastic properties for the mesoscale model are measured over a range of temperatures using a sonic resonance technique. Effective properties for the macroscale are obtained over a range of mesoscale geometries and can be obtained without needing to rerun the mesoscale simulations. The effective properties are experimentally validated using four-point bend experiments on representative samples. The bulk properties and the effective properties can then be used as material inputs for the macroscale model in order to design cells that are more sufficiently mechanically robust without sacrificing electrochemical performance.

Holistic Measurement in the Sheet-Bulk Metal Forming Process with Fringe Projection

2012 ◽  
Vol 504-506 ◽  
pp. 1005-1010 ◽  
Author(s):  
Christoph Ohrt ◽  
Wito Hartmann ◽  
Johannes Weickmann ◽  
Markus Kästner ◽  
Albert Weckenmann ◽  
...  
Keyword(s):  
Metal Forming ◽  
Optical Measurement ◽  
Fringe Projection ◽  
Small Scale ◽  
Work Piece ◽  
Forming Process ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Deviation Analysis ◽  
Metal Forming Process

Sheet bulk metal forming is a new forming technology, currently developed by several companies and research institutes. It creates high demands on the inspection of parts and tools, especially in the field of in-situ abrasion detection of the forming tool and its impacts on the work piece. This manuscript introduces two optical testing methods for fulfilling these inspection tasks: On the one hand the endoscopic fringe projection as a flexible small scale optical measurement principal with high depth of focus and accuracy for the acquisition of filigree form elements for a continuous abrasion determination and one the other hand the multi-scaled fringe projection for a holistic one shot measurement of the work piece for an adapted, multiscale deviation analysis. The development and advantages of both systems for the sheet bulk metal forming process are shown as well as potentials of the combination of the both systems close to the proposed application next to the production line.

On Applying Kriging Approximate Optimization to Sheet Metal Forming

2011 ◽  
Vol 63-64 ◽  
pp. 3-7
Author(s):  
Yan Min Xie
Keyword(s):  
Sheet Metal ◽  
Process Parameters ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Nonlinear Function ◽  
Kriging Model ◽  
Engineering Problem ◽  
Forming Process ◽  
Element Analysis ◽  
Metal Forming Process

This paper presents a methodology to effectively determine the optimal process parameters using finite element analysis (FEA) and design of experiments (DOE) based on Metamodels. The idea is to establish an approximation function relationship between quality objectives and process parameters to alleviate the expensive computational expense in the optimization iterations for the sheet metal forming process. This paper investigated the Kriging metamodel approach. In order to prove accuracy and efficiency of Kriging method, the nonlinear function as test functions is implemented. At the same time, the practical nonlinear engineering problems such as square drawing are also optimized successfully by proposed method. The results prove Kriging model is an effective method for nonlinear engineering problem in practice.

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