Optimization of the loading path for the tube-hydroforming process

2016 ◽  
Vol 230 (12) ◽  
pp. 1605-1623 ◽  
Author(s):  
Hwan-Hak Jang ◽  
Youngmyung Lee ◽  
Gyung-Jin Park
Keyword(s):  
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.

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.

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.

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