Experimental Research and Numerical Simulation Analysis for Hydroforming of an Instrument Panel Beam

2013 ◽  
Vol 395-396 ◽  
pp. 966-969
Author(s):  
Xue Yi Wang ◽  
Zai Xiang Zheng ◽  
Wen Shan Wang ◽  
Wei Wei Zhang
Keyword(s):  
Numerical Simulation ◽  
Internal Pressure ◽  
Simulation Analysis ◽  
Tube Hydroforming ◽  
Instrument Panel ◽  
Pressure Load ◽  
Axial Feeding ◽  
Hydroforming Process ◽  
Critical Process Parameters ◽  
Critical Process

Due to the apparent advantages of tube hydroforming technology in reducing weight and energy consumption, and saving material and cost, it has been applied in the production of instrument panel beam. By constructing the FEM models of instrument panel beam, three numerical simulation schemes are designed according to the matching relationship between internal pressure load and axial feeding. Then the simulation results are given and compared with the experimental data. The simulation and experimental analysis indicate that the optimal matching relationship between internal pressure load and axial feeding influences hydroforming result of parts. It provides a theoretical reference for the design of hydroforming process and its die, and the setting of critical process parameters.

Investigation on the Effect of Pulsating Pressure on Tube-Hydroforming Process

2011 ◽  
Vol 473 ◽  
pp. 618-623
Author(s):  
Khalil Khalili ◽  
Seyed Yousef Ahmadi-Brooghani ◽  
Amir Ashrafi
Keyword(s):  
Finite Element ◽  
Internal Pressure ◽  
Thickness Distribution ◽  
Tube Hydroforming ◽  
Element Model ◽  
Fe Model ◽  
Axial Feeding ◽  
Hydroforming Process ◽  
The Finite Element Model ◽  
Good Agreement

Tube hydroforming process is one of the metal forming processes which uses internal pressure and axial feeding simultaneously to form a tube into the die cavity shape. This process has some advantages such as weight reduction, more strength and better integration of produced parts. In this study, T-shape tube hydroforming was analyzed by experimental and finite element methods. In Experimental method the pulsating pressure technique without counterpunch was used; so that the internal pressure was increased up to a maximum, the axial feeding was then stopped. Consequently, the pressure decreased to a minimum. The sequence was repeated until the part formed to its final shape. The finite element model was also established to compare the experimental results with the FE model. It is shown that the pulsating pressure improves the process in terms of maximum protrusion height obtained. Counterpunch was eliminated as being unnecessary. The results of simulation including thickness distribution and protrusion height were compared to the part produced experimentally. The result of modeling is in good agreement with the experiment. The paper describes the methodology and gives the results of both experiment and modeling.

Corner Fill Modeling of Tube Hydroforming

2000 ◽  
Author(s):  
J. Y. Chen ◽  
Z. C. Xia ◽  
S. C. Tang
Keyword(s):  
Numerical Experiment ◽  
Internal Pressure ◽  
Process Design ◽  
Tube Hydroforming ◽  
Design Guidelines ◽  
Structural Components ◽  
Round Tube ◽  
Fundamental Understanding ◽  
Hydroforming Process ◽  
Square Box

Abstract Hydroforming process provides important advantages for automotive structural components over conventional stamp-and-weld parts, but it also brings unique challenges in process design. This paper attempts to obtain fundamental understanding of the process through corner fill modeling. A round tube is pressurized to expand into a square box with tight radius in the numerical experiment. Several parameters are identified and investigated during the process, namely, the internal pressure, end feed, and the lubricant. Their effects on the deformation profiles are presented, and their importance in process design is discussed. The established design guidelines from the study can be a valuable tool for hydroforming process engineers and part designers.

Tube Hydroforming Analysis Based on Ansys

2012 ◽  
Vol 232 ◽  
pp. 537-540
Author(s):  
Xiao Yu Yang
Keyword(s):  
Internal Pressure ◽  
Tube Hydroforming ◽  
Ansys Software ◽  
Paper Briefly ◽  
Hydroforming Process

This paper briefly introduces some problems of tube hydroforming process, at the same time, also uses Ansys software to simulate in tube hydroforming process. And draw an conclusion，To avoid defects in tube hydroforming process, the applied internal pressure must be high enough to suppress buckling but not too high to cause bursting.

Optimization using finite element analysis, neural network, and experiment in tube hydroforming of aluminium T joints

2007 ◽  
Vol 221 (8) ◽  
pp. 1299-1305 ◽  
Author(s):  
F Mohammadi ◽  
H Kashanizade ◽  
M Mosavi Mashadi
Keyword(s):  
Neural Network ◽  
Finite Element ◽  
Internal Pressure ◽  
Objective Function ◽  
Tube Hydroforming ◽  
Optimization Methods ◽  
Loading Path ◽  
Complex Method ◽  
T Joints ◽  
Axial Feeding

In tube hydroforming (THF) of T joints, loading conditions (internal pressure and axial feeding) should be determined in such a way that the tube does not wrinkle or burst and is fully calibrated. In the current study THF of an aluminium T joint is simulated with the finite element method (FEM) using a commercial code. An explicit method is used to overcome convergence problems that are encountered in an implicit method. Internal pressure and axial feeding are two variables in the optimization problem and the loading path is optimized. The objective function is the clamping force, and the constraints of wrinkling, minimum thickness, and calibration should be achieved. The objective and constraint functions are obtained by training a neural network and the objective function is minimized using several optimization methods including hill-climbing search, simulated annealing, and complex method. The axial feeding and internal pressure obtained by optimization methods are used to conduct an experiment. Thickness distribution, calibration pressure, and axial feeding in experiment and FEM are compared and it is shown that there is a good agreement between them.

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.

Numerical Simulation of Rubber Bladder Hydroforming Process for Shrink Flanging Parts with Large Curvature

2012 ◽  
Vol 430-432 ◽  
pp. 1286-1289
Author(s):  
Ming He Chen ◽  
Fu Dong Wang ◽  
Jie Xiong
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Simulation Analysis ◽  
Hydraulic Press ◽  
Blank Holder ◽  
Finite Element Software ◽  
Hydroforming Process ◽  
Rubber Forming ◽  
Main Defect ◽  
Dip Angle

The main defect of shrink flanging wing rib is wrinkling in rubber bladder hydroforming. In the aeronautical field, the side blank holder is usually used to avoid wrinkling. In order to obtain appropriate parameters of side blank holder, it be carried out that the simulation analysis for the process of the high hydraulic press rubber forming processes of high shrink flanging with side blank holder by the ABAQUS finite element software. Besides, the corresponding experiments verified also be implemented. The research results show that the sheet metal tends to wrinkle along with decrease of the blank lap width and increase of these parameters such as the distance between side blank holder and die, the dip angle and fillet radius of the side blank holder.

Study of Forming Parameters in Hydroforming of a Thin-Walled ASTM C11000 Copper Tube

2009 ◽  
Vol 83-86 ◽  
pp. 133-142
Author(s):  
S.M.H. Seyedkashi ◽  
Golam Hosein Liaghat ◽  
Hassan Moslemi Naeini ◽  
M. Hoseinpour Gollo
Keyword(s):  
Internal Pressure ◽  
Tube Wall ◽  
Tube Hydroforming ◽  
Contact Friction ◽  
Effective Parameters ◽  
Axial Feeding ◽  
Loading Paths ◽  
Wall Thinning ◽  
Non Linear ◽  
A New Technique

Tube hydroforming technology is still considered a new technique growing fast in automotive and aircraft industries. Many researches on all aspects of this process are still required. Contact friction is one of the most effective parameters on tube wall thinning. To successfully fulfill the process without any common defects, it is very important to determine the proper internal pressure and axial feeding loading paths. In this paper, the effect of lubrication on tube wall thinning on ASTM C11000 copper alloy is discussed as well as the effect of internal pressure and axial feeding. An axisymmetric bulged tube is investigated using theoretical, numerical and experimental methods. Improved linear and non-linear pressure and feeding loading paths are applied and the predicted results are experimentally proved. It is observed that non-linear pressure application gives smoother results. Also proper lubrication plays an important role in success of the process.

Preform Design for Formability Enhancement of Tube Hydroforming Process Using Deformation History

2007 ◽  
Vol 340-341 ◽  
pp. 593-598
Author(s):  
Woo Jin Song ◽  
Han Ho Choi ◽  
Keun Hwan Kim ◽  
Sung Ho Park ◽  
Jeong Kim ◽  
...  
Keyword(s):  
Internal Pressure ◽  
Production Cost ◽  
General Procedure ◽  
Tube Hydroforming ◽  
Numerical Approach ◽  
Preform Design ◽  
Trial And Error ◽  
Deformation History ◽  
Optimum Configuration ◽  
Hydroforming Process

Preform design in tube hydroforming implies the design of an intermediate shape between initial tube and the final product enabling to be fabricated without defects and excessive loss of material. A carefully selected preform can contribute significantly to reduce production cost and improve formability, since thinned sections may not be able to endure internal pressure during expansion whereas excessive thickening may lead to wrinkles. Generally, preform design in hydroforming was mainly carried out through the trial-and-error approach. Even though a series of numerical simulations for several predetermined preformed shapes were conducted, optimum configuration could not be obtained and could not be suggested the general procedure for preform design as well. In this work, a simple numerical approach to the preform design for formability enhancement was introduced based on the deformation history during forward hydroforming simulation. The proposed approach was implemented to a hydroforming process of an automobile subframe component in order to be satisfied the required specification after hydroforming, and the conceptual application has been proved to be successful on its effectiveness and feasibility. Therefore, it is shown that preform design approach proposed in this study will provide one of feasible methods to satisfy the increasing practical demands for improvement of the formability in hydroforming processes.

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.

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