FEM Simulation and Optimization of Process Parameters for Tube Hydroforming

2011 ◽  
Vol 101-102 ◽  
pp. 901-904 ◽  
Author(s):  
Cheng Zhan Chen ◽  
Yi Gan ◽  
Ji Tao Du ◽  
Can Huang ◽  
Qi Jun Chen
Keyword(s):  
Process Parameters ◽  
Thickness Distribution ◽  
Tube Hydroforming ◽  
Fem Simulation ◽  
Reference Value ◽  
Variable Cross Section ◽  
Variable Cross ◽  
Simulation And Optimization ◽  
Finite Element Software ◽  
Hydroforming Process

The finite element software DYNAFORM was applied to simulate the whole tube hydroforming process. Two main failure types in the process of hydroforming are wrinkling and bursting. The strain distribution and thickness distribution at different process parameters were presented. Not only friction coefficient but also the effect of different matching of internal pressure and axial force was simulated and analyzed. In addition, the velocity of punch was considered too. The result has reference value for the variable cross-section tube hydroforming process research.

Study on Influence of the Load Path on Formability of Variable Cross-Section Y-Shaped Tube Hydroforming

2013 ◽  
Vol 347-350 ◽  
pp. 1153-1157
Author(s):  
Hai Ying Zhang ◽  
Ling Bai ◽  
Guo Jun Zhang ◽  
Rui Mao ◽  
Wen Liu
Keyword(s):  
Cross Section ◽  
Tube Hydroforming ◽  
Fem Simulation ◽  
Variable Cross Section ◽  
Variable Cross ◽  
Load Path ◽  
Line Load ◽  
Evaluation Indexes ◽  
Shaped Tube ◽  
Simulation Results

Based on the analysis of now available evaluation indexes to estimate the formability of Variable cross-section Y-shaped tube hydroforming, an aggregative indicator is proposed. The effect of load path on the formability of Variable cross-section Y-shaped tube is discussed by FEM simulation, and validity of the evaluation index and simulations are proved by experiment. Results show that with the broken line load path of 0-30-30-40, the value of aggregative indicator is the greatest and the formability is the best. The optional parameters are testified by experiment and the results are in agreement with the FEM simulation results.

FEM Simulation of Different Loading Pressures on T-Tube Hydroforming

2012 ◽  
Vol 472-475 ◽  
pp. 670-673
Author(s):  
Ji Ping Chen ◽  
Jian Qing Qian ◽  
Sheng Zhi Li
Keyword(s):  
Constant Pressure ◽  
Thickness Distribution ◽  
Tube Hydroforming ◽  
Fem Simulation ◽  
Load Path ◽  
T Tube ◽  
Pressure Load ◽  
Load Paths ◽  
Hydroforming Process ◽  
Internal Pressures

The finite element simulation of T-tube hydroforming process is conducted with the FEM software Pam-Stamp 2G 2005. The results of numerical simulation and experiment are compared and analyzed. The tube hydroforming simulations under various internal pressures of constant pressure load path are also conducted. The simulation and experimental results of T-tube hydroforming are compared. The results show that the tube wall thickness distribution is more uniform and the hydroforming effect is more ideal in T-tube hydroforming process with constant pressure load path. The constant pressure load path of T-tube hydroforming is relatively easy to implement in the practical production process. Of the four constant pressure load paths of T-tube hydroforming, the simulation result under constant pressure 150MPa is most ideal.

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.

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.

A Numerical Study on Tube Hydroforming Process to optimize the Process Parameters by Taguchi Method

2018 ◽  
Vol 5 (11) ◽  
pp. 25376-25381 ◽  
Author(s):  
P. Venkateshwar Reddy ◽  
B. Veerabhadra Reddy ◽  
P. Srinivasa Rao
Keyword(s):  
Taguchi Method ◽  
Process Parameters ◽  
Numerical Study ◽  
Tube Hydroforming ◽  
Hydroforming Process

Numerical and Experimental Study of the Effect Pressure Path in Tube Hydroforming Process

2011 ◽  
Vol 473 ◽  
pp. 579-586
Author(s):  
Majid Elyasi ◽  
Hassan Khanlari ◽  
Mohammad Bakhshi-Jooybari
Keyword(s):  
Experimental Study ◽  
Finite Element ◽  
Stainless Steel ◽  
Experimental Approach ◽  
Thickness Distribution ◽  
Tube Hydroforming ◽  
Initial Pressure ◽  
Low Carbon ◽  
Element Simulation ◽  
Hydroforming Process

In this paper, the effect of pressure path on thickness distribution and product geometry in the tube hydroforming process is studied by finite element simulation and experimental approach. In simulations and experiments, low carbon stainless steel (SS316L) seamless tubes were used. The obtained results indicated that with increasing of the initial pressure, the bulge value of the part increases and the wrinkling value decreases. In addition, if the initial pressure is highly decreased, then bursting may occur.

FE Simulation and Experimental Study of Tube Hydroforming Process for AA1050 Alloy at Various Temperatures

2011 ◽  
Vol 264-265 ◽  
pp. 96-101
Author(s):  
Hassan Moslemi Naeini ◽  
Golam Hosein Liaghat ◽  
S.J. Hashemi Ghiri ◽  
S.M.H. Seyedkashi
Keyword(s):  
Elevated Temperatures ◽  
New Technologies ◽  
Thickness Distribution ◽  
Tube Hydroforming ◽  
Thermal Conditions ◽  
High Strength ◽  
Different Temperatures ◽  
Hydroforming Process ◽  
Production Technologies ◽  
Advanced Production

Considering the necessity of using light weight, high strength and corrosion resistant materials, automotive and aerospace industries need to use advanced production technologies. Hydroforming has been regarded as one of the new technologies in forming of aluminium and magnesium alloys. These alloys have very low formability at room temperature which will be improved at elevated temperatures. In this paper, AA1050 aluminium alloy tube is numerically and experimentally investigated at different temperatures. Thickness distribution in forming zone is studied under different thermal conditions. Numerical results have been verified by experiments and there is a good agreement.

Two Dimensional Plane Strain Modeling of Tube Hydroforming

2000 ◽  
Author(s):  
G. T. Kridli ◽  
L. Bao ◽  
P. K. Mallick
Keyword(s):  
Finite Element ◽  
Plane Strain ◽  
Material Properties ◽  
Thickness Distribution ◽  
Tube Hydroforming ◽  
Strain Hardening Exponent ◽  
Hydraulic Pressure ◽  
Two Dimensional ◽  
Dimensional Plane ◽  
Hydroforming Process

Abstract The tube hydroforming process has been used in industry for several years to produce components such as exhaust manifolds. Recent advances in forming machines and machine control systems have allowed for the introduction and the implementation of the process to produce several automotive components, which were originally produced by the stamping process. Components such as side rails, engine cradles, space frames, and several others can be economically produced by tube hydroforming. The process involves forming a straight or a pre-bent tube into a die cavity using internal hydraulic pressure, which may be coupled with controlled axial feeding of the tube. One of the remaining challenges facing product and process engineers in designing hydroformed parts is the lack of an extensive knowledge base of the process. This includes a full understanding of the process mechanics and the effects of the material properties on the quality of the hydroformed product. This paper reports on the results of two dimensional plane strain finite element models of the tube hydroforming process, which were conducted using the commercial finite element code ABAQUS/Standard. The objective of the study is to examine the effects of material properties, die geometry, and frictional characteristics on the selection of the hydroforming process parameters. The paper discusses the effects of the strain-hardening exponent, friction coefficient at the die-workpiece interface, initial tube wall thickness, and die corner radii on the thickness distribution of the hydroformed tube.

Numerical – Experimental Correlation of Sheet Hydroformed Component

2015 ◽  
Vol 651-653 ◽  
pp. 1140-1145
Author(s):  
Alessandro Spagnolo ◽  
Teresa Primo ◽  
Gabriele Papadia ◽  
Antonio del Prete
Keyword(s):  
Finite Element ◽  
Process Parameters ◽  
Complex Geometry ◽  
Thickness Distribution ◽  
Fluid Pressure ◽  
Experimental Tests ◽  
Element Analysis ◽  
Influence Of Process Parameters ◽  
Experimental Correlation ◽  
Hydroforming Process

Sheet hydroforming has gained increasing interest in the automotive and aerospace industries because of its many advantages such as higher forming potentiality, good quality of the formed parts which may have complex geometry. The main advantage is that the uniform pressure can be transferred to any part of the formed blank at the same time. This paper reports numerical and experimental correlation for symmetrical hydroformed component. Experimental tests have been carried out through the hydroforming cell tooling, designed by the authors thanks to a research project, characterized by a variable upper blankholder load of eight different hydraulic actuators. The experimental tests have been carried out following a factorial plane of two factors, with two different levels for each factor and three replicates for each test with a total of 12 tests. In particular two process parameters have been considered: blank holder force, die fluid pressure. Each factor has been varied between an High (H) and Low level (L). The order in which have been conducted the tests has been established through the use of the Minitab software, in order to ensure the data normality and the absence of auto-correlation between the tests. An ANOVA analysis has been performed, in addition, with the aim of evaluating the influence of process parameters on the thickness distribution of the component, its formability and feasibility. Finally, finite element analysis (FEA) was used to understand the formability of a material during the hydroforming process. In this paper, the commercial finite element code LS-Dyna was used to run the simulations. A good numerical – experimental correlation has been obtained.

Investigation of Load Path Effect on Thickness Distribution and Product Geometry in the Bulge Hydroforming Process

2011 ◽  
Vol 110-116 ◽  
pp. 1477-1482 ◽  
Author(s):  
Majid Elyasi ◽  
Hassan Khanlari ◽  
Mohammad Bakhshi-Jooybari
Keyword(s):  
Finite Element ◽  
Stainless Steel ◽  
Finite Element Simulation ◽  
Experimental Approach ◽  
Thickness Distribution ◽  
Tube Hydroforming ◽  
Low Carbon ◽  
Load Path ◽  
Element Simulation ◽  
Hydroforming Process

In this paper, the effect of load path on thickness distribution and product geometry in the tube hydroforming process is studied by finite element simulation and experimental approach. The pressure path was obtained by using finite element simulation and its validation with experiments. In simulations and experiments, low carbon stainless steel (SS316L) seamless tubes were used. The obtained results indicated that if pressure reaches to maximum faster, bulge value and thinning of the part will be more and wrinkling value will be less.

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