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.

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.

Numerical Simulation and Optimization of a Tee Shaped Tube Hydroforming Process

2006 ◽  
Author(s):  
J. Crapps ◽  
H. Fang ◽  
M. F. Horstemeyer
Keyword(s):  
Multiobjective Optimization ◽  
Tube Hydroforming ◽  
Industrial Process ◽  
Material Model ◽  
Simulation And Optimization ◽  
History Effects ◽  
Shaped Tube ◽  
Hydroforming Process ◽  
Optimization Methodology ◽  
Using Data

We performed numerical simulations and multiobjective optimization of a hydroforming process for copper tees using the BCJ plasticity material model developed by Bammann et al., which accounts for material manufacturing and history effects. A finite element simulation of the hydroforming process was created using data from experiments and the industrial process. The process parameters and geometry factors were optimized using a multiobjective optimization methodology employing metamodeling and software developed at Mississippi State University’s Center for Advanced Vehicular Systems.

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.

Prediction of failure in tube hydroforming process using a damage model

2007 ◽  
Vol 21 (10) ◽  
pp. 1512-1517 ◽  
Author(s):  
G. H. Majzoobi ◽  
F. Freshteh Saniee ◽  
A. Shirazi
Keyword(s):  
Damage Model ◽  
Tube Hydroforming ◽  
Hydroforming Process

Assortment of Hydroforming Fluid for Extreme Pressure and Anti Wear Properties

2019 ◽  
Author(s):  
S. P. Rudraksha ◽  
S. H. Gawande
Keyword(s):  
Tube Hydroforming ◽  
Vital Role ◽  
Test Method ◽  
Lubricating Oil ◽  
Experimental Investigations ◽  
Extreme Pressure ◽  
Wear Properties ◽  
Premature Failure ◽  
Hydroforming Process

Abstract Lubricants play vital role in tube hydroforming (THF) process to reduce friction between tool and die wall interface which helps to enhance the quality of finished product. The process parameters and quality of components is influence by the friction between the tube and inner surface of the die. Excellent lubricant reduces the problem of wrinkling, buckling and premature failure of the component. Extreme pressure, Anti-wear, and frictional properties of fluid influence the performance of tube hydroforming process. In this paper EP (extreme pressure), anti-wear and friction properties of hydroforming lubricating oils as Enklo68, Enklo46, Enklo32 and Enklo100 are investigated. Test method as per ASTM standards is used for the measurement of EP and wear preventive properties of hydroforming fluids by using Ball Tester TR – 30L under atmospheric pressure of lubricating oil at 392 N load and 75°C temperature with constant speed of 1770 rpm. From experimental investigations it is observed that as Enklo68 is more suitable hydroforming fluid as compared to Enklo46, Enklo32 and Enklo100 as its observed coefficient of friction (i.e. 0.10581) is very less.

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