scholarly journals Warm Hydroforming Process under Non-Uniform Temperature Field for Magnesium Alloy Tubes

Metals ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 901
Author(s):  
Toshiji Morishima ◽  
Ken-Ichi Manabe
Keyword(s):  
Temperature Distribution ◽  
Magnesium Alloy ◽  
Thickness Distribution ◽  
Tube Hydroforming ◽  
Fuzzy Model ◽  
Fe Analysis ◽  
Experimental Result ◽  
Loading Path ◽  
Analysis Model ◽  
Warm Hydroforming

The warm tube hydroforming (WTHF) process of lightweight materials such as magnesium alloy contributes to a remarkable weight reduction. The success of the WTHF process strongly depends on the loading path with internal pressure and axial feeding and other process variables including temperature distribution. Optimization of these process parameters in this special forming technique is a great issue to be resolved. In this study, the optimization of the symmetrical temperature distribution and process loading path for the warm T-shape forming of magnesium alloy AZ31B tube was carried out by finite element (FE) analysis using a fuzzy model. As a result, a satisfactory good agreement of the wall thickness distribution of the samples formed under the optimum loading path condition can be obtained between the FE analysis result and the experimental result. Based on the validity validation of FE analysis model, the optimization method was applied to other materials and forming shapes, and applicability was discussed.

Warm Hydroforming Process with Non-Uniform Heating for AZ31 Magnesium Alloy Tube

2010 ◽  
Vol 654-656 ◽  
pp. 739-742 ◽  
Author(s):  
Kenichi Manabe ◽  
Toshiji Morishima ◽  
Yu Ogawa ◽  
Kazuo Tada ◽  
Tsutomu Murai ◽  
...  
Keyword(s):  
Finite Element ◽  
Temperature Distribution ◽  
Magnesium Alloy ◽  
Tube Hydroforming ◽  
Az31 Magnesium Alloy ◽  
Fe Model ◽  
Uniform Heating ◽  
Forming Process ◽  
Alloy Tube ◽  
Warm Hydroforming

In this study, non-uniform heating approach in warm T-joint forming process is attempted for the AZ31 magnesium alloy tube. For this purpose, finite element simulation is performed to analyze the appropriate temperature distribution. The validity of the finite element(FE) model of T-joint tube hydroforming(THF) is verified by comparing the FE simulation and experimental results. Using this FE model, appropriate temperature distribution was suggested. In addition, it was showed that the wall thickness could be more uniform by optimizing the temperature condition.

125 Effect of Temperature Distribution in Warm Hydroforming of AZ31 Magnesium Alloy Tube

2009 ◽  
Vol 2009.17 (0) ◽  
pp. _125-1_-_125-2_
Author(s):  
Ken-ichi MANABE ◽  
Yu OGAWA ◽  
Kazuo TADA ◽  
Tsutomu MURAI ◽  
Humiaki NAKAGAWA
Keyword(s):  
Temperature Distribution ◽  
Magnesium Alloy ◽  
Az31 Magnesium Alloy ◽  
Effect Of Temperature ◽  
Alloy Tube ◽  
Warm Hydroforming

Adaptive Simulations of T-Shape Tube Hydroforming Processes

2007 ◽  
Vol 340-341 ◽  
pp. 627-632 ◽  
Author(s):  
Yeong-Maw Hwang ◽  
Bing Hong Chen ◽  
Wen Chan Chang
Keyword(s):  
Finite Element ◽  
Internal Pressure ◽  
Adaptive Algorithm ◽  
Thickness Distribution ◽  
Tube Hydroforming ◽  
Loading Path ◽  
Finite Element Code ◽  
Simulation Results ◽  
Formed Product ◽  
The Relationship

A successful THF process depends largely on the loading paths for controlling the relationship between the internal pressure, axial feeding and the counter punch. In this study, an adaptive algorithm combined with a finite element code LS-DYNA 3D is proposed to control the simulation of T-shape hydroforming with a counter punch. The effects of the friction coefficients at the interface between the tube and die on the loading path and thickness distribution of the formed product are discussed. Experiments of protrusion hydroforming are also conducted. The final shape and thickness distribution of the formed product are compared with the simulation results to verify the validity of this modeling.

Progress on High Pressure Pneumatic Forming and Warm Hydroforming of Titanium and Magnesium Alloy Tubular Components

2014 ◽  
Vol 783-786 ◽  
pp. 2456-2461 ◽  
Author(s):  
Gang Liu ◽  
Yong Wu ◽  
Jian Long Wang ◽  
Wen Da Zhang
Keyword(s):  
High Pressure ◽  
Temperature Field ◽  
Magnesium Alloy ◽  
Thickness Distribution ◽  
Expansion Ratio ◽  
Mg Alloy ◽  
Ti Alloy ◽  
Warm Hydroforming ◽  
Corner Filling ◽  
Tubular Components

Complex structural tubular components of Titanium and Magnesium alloy can be obtained at a certain temperature by high pressure pneumatic forming (HPPF) with gas medium or warm hydroforming with pressurized liquid medium. At 800°C, through experimental research on HPPF of TA18 Ti-alloy tube with expansion ratio of 50%, the influence of axial feeding on thickness distribution of the workpiece was studied. Using reasonable loading curve, the component with large ratio can be formed with a small thinning ratio as 13% with total axial feeding amount of 40mm. At 850°C, HPPF experiments of TA18 Ti-alloy component with square section were carried out. The influence of gas pressure on thickness distribution and corner filling process were analyzed. The larger the pressure, the sooner the displacement changes at the corner, and the shorter corner filling term. At pressure of 30 MPa, small corner with the relative corner radius of 2.0 can be obtained within 168s. For Mg-alloy tubular part, warm hydroforming with non-uniform temperature field was studied. By using reasonable axial temperature field and loading path, the maximum thinning ratio of Mg-alloy tubular component with expansion ratio of 35% was reduced from 21.6% to 11.6%.

scholarly journals Thickness Improvement and Calibration Pressure Reduction of Stepped Tubular Components Using Axial Hydro-pressing Method

2021 ◽  
Author(s):  
Cong Han ◽  
Yongpeng Zhuang ◽  
Jing Li
Keyword(s):  
Wall Thickness ◽  
Thickness Distribution ◽  
Tube Hydroforming ◽  
Pressure Rise ◽  
Loading Path ◽  
Pressing Method ◽  
Feeding Pressure ◽  
Cooperation Relationship ◽  
The Relationship ◽  
Tubular Components

Abstract A new tube axial hydro-pressing method was proposed to solve the problems of high forming pressure and severely uneven wall thickness distribution of traditional tube hydroforming methods to form stepped tubular components. The forming pressure of the traditional hydroforming and the tube axial hydro-pressing method is studied theoretically, the mechanical model of the fillet area is established, and the forming pressure calculation formula is given. Based on this, an investigation of the tube axial hydro-pressing method is carried out by numerical simulation and experimental methods, and compared with the traditional tube hydroforming method. The key to the tube axial hydro-pressing method is to precisely control the relationship between the protrusion height and the axial feed, which is achieved by precisely controlling the feeding pressure and the axial displacement. Therefore, the constant pressure device in the experiment was used to eliminate the influence of the pressure rise caused by the volume compression on its cooperation relationship, to achieve accurate control of the loading path, eliminate wrinkles and flash defects. A qualified workpiece is successfully manufactured when the internal pressure is 18.0 MPa and the feed on each side is 15.0 mm. The forming pressure is reduced by 88.0%, and the feed is increased by 6.5%, which reduces the wall thickness reduction by 9.0%. The wall thickness difference of the workpiece can be controlled within 7.0%. The tube axial hydro-pressing method is suitable for forming stepped tubular components, which can achieve more replenishment at lower pressures, thereby effectively improving the uniformity of wall thickness and significantly reducing the forming pressure.

Prediction of Wrinkling and Bursting in Hydroforming of Tubes in Box-Shaped Die Using FEM

2011 ◽  
Vol 486 ◽  
pp. 213-216
Author(s):  
Amir Masoud Mirhosseini ◽  
Mohsen Loh Mousavi ◽  
Ghasem Amirian
Keyword(s):  
Thickness Distribution ◽  
Tube Hydroforming ◽  
Experimental Tests ◽  
Loading Path ◽  
Technical Knowledge ◽  
Optimal Range ◽  
Axial Feeding ◽  
Shaped Part ◽  
Dynamic Software ◽  
Explicit Dynamic

In recent years, tube hydroforming has been considered by automobile and airplane industries, because it decreases weight and increases solidity of parts. For this reason, technical knowledge for manufacturing with better quality and accuracy has been developing. However, there are some probable defects in forming by hydroforming technique, which are bursting and wrinkling caused by improper loading paths. Therefore, it is very important to apply a proper path pressure proportional to axial feeding. In this research, firstly, tube hydroforming in a box-shaped die has been simulated by means of 3-D FEM in explicit dynamic software ABAQUSE 6.9-1. For prediction of these occurrences, different paths of pressure have been analyzed and then by comparison with obtained results from the simulation performed such as thickness distribution and final form of the tube, the range of pressure and axial feeding have been predicted. Accordingly, optimal range and loading path for hydroforming of box-shaped part without failure is determined. Considering the working conditions related to the same experimental tests and comparing these conditions with simulated results, efficiency and accuracy of the proposed method have been also investigated.

scholarly journals Finite-Element Modelling of Double-Roller Clamping Spinning of Wind Concentrator

2022 ◽  
Vol 9 ◽  
Author(s):  
Xueyong Qu ◽  
Hongzhong Xu ◽  
Shuqin Fan ◽  
Xiaole Cheng ◽  
Shengdun Zhao ◽  
...  
Keyword(s):  
Finite Element ◽  
Complex Shape ◽  
Thickness Distribution ◽  
Fe Analysis ◽  
Fe Model ◽  
Analysis Model ◽  
Forming Process ◽  
Wall Thickness Distribution ◽  
Plastic Deformation Behavior ◽  
Spinning Process

In order to improve the unit-power of a wind-driven generator, a wind concentrator with complex shape is installed in front of the impeller, which makes the airflow integrated and accelerated. It is important to manufacture the wind concentrator with high precision. The double-roller clamping spinning (DRCS) is a dieless, flexible spinning process that is very suitable for forming a wind concentrator with complex shape. The profile of a wind concentrator is divided into two parts: the contraction section and the expanding section. The process routes of both the contraction section and the expanding section are determined, and roller path equations are derived. Then the finite element (FE) analysis model that can describe the plastic deformation behavior of the DRCS forming for a wind concentrator is established, and the DRCS process of the flange is simulated. Furthermore, the wall-thickness distribution on the expanding section during the forming process is obtained. Finally, the reliability of the FE model is verified using the experimental results.

Optimization of Tube Hydroforming Process Using Probabilistic Constraints on Failure Modes

2011 ◽  
Vol 62 ◽  
pp. 21-35 ◽  
Author(s):  
Anis Ben Abdessalem ◽  
A. El Hami
Keyword(s):  
Failure Modes ◽  
High Reliability ◽  
Thickness Distribution ◽  
Tube Hydroforming ◽  
Forming Limit Diagram ◽  
Plastic Instability ◽  
Probabilistic Constraints ◽  
Forming Limit ◽  
Reliability Based Design ◽  
Hydroforming Process

In metal forming processes, different parameters (Material constants, geometric dimensions, loads …) exhibits unavoidable scatter that lead the process unreliable and unstable. In this paper, we interest particularly in tube hydroforming process (THP). This process consists to apply an inner pressure combined to an axial displacement to manufacture the part. During the manufacturing phase, inappropriate choice of the loading paths can lead to failure. Deterministic approaches are unable to optimize the process with taking into account to the uncertainty. In this work, we introduce the Reliability-Based Design Optimization (RBDO) to optimize the process under probabilistic considerations to ensure a high reliability level and stability during the manufacturing phase and avoid the occurrence of such plastic instability. Taking account of the uncertainty offer to the process a high stability associated with a low probability of failure. The definition of the objective function and the probabilistic constraints takes advantages from the Forming Limit Diagram (FLD) and the Forming Limit Stress Diagram (FLSD) used as a failure criterion to detect the occurrence of wrinkling, severe thinning, and necking. A THP is then introduced as an example to illustrate the proposed approach. The results show the robustness and efficiency of RBDO to improve thickness distribution and minimize the risk of potential failure modes.

SURFACE ROUGHNESS OF MAGNESIUM ALLOY AZ91D IN HIGH SPEED MILLING

2016 ◽  
Vol 78 (6-9) ◽  
Author(s):  
Mohd Shahfizal Ruslan ◽  
Kamal Othman ◽  
Jaharah A.Ghani ◽  
Mohd Shahir Kassim ◽  
Che Hassan Che Haron
Keyword(s):  
Surface Roughness ◽  
Magnesium Alloy ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Parameters ◽  
Experimental Result ◽  
Depth Of Cut ◽  
Polishing Process ◽  
High Speed Cutting ◽  
Radial Depth

Magnesium alloy is a material with a high strength to weight ratio and is suitable for various applications such as in automotive, aerospace, electronics, industrial, biomedical and sports. Most end products require a mirror-like finish, therefore, this paper will present how a mirror-like finishing can be achieved using a high speed face milling that is equivalent to the manual polishing process. The high speed cutting regime for magnesium alloy was studied at the range of 900-1400 m/min, and the feed rate for finishing at 0.03-0.09 mm/tooth. The surface roughness found for this range of cutting parameters were between 0.061-0.133 µm, which is less than the 0.5µm that can be obtained by manual polishing. Furthermore, from the S/N ratio plots, the optimum cutting condition for the surface roughness can be achieved at a cutting speed of 1100 m/min, feed rate 0.03 mm/tooth, axial depth of cut of 0.20 mm and radial depth of cut of 10 mm. From the experimental result the lowest surface roughness of 0.061µm was obtained at 900 m/min with the same conditions for other cutting parameters. This study revealed that by milling AZ91D at a high speed cutting, it is possible to eliminate the polishing process to achieve a mirror-like finishing.

Sign in / Sign up

Export Citation Format

Share Document