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.

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.

Evolution of Hydroforming Technologies and Its Applications — A Review

2020 ◽  
Vol 19 (04) ◽  
pp. 737-780
Author(s):  
P. Venkateshwar Reddy ◽  
B. Veerabhadra Reddy ◽  
P. Janaki Ramulu
Keyword(s):  
Tube Hydroforming ◽  
High Strength Steels ◽  
High Strength ◽  
Lightweight Materials ◽  
Hydroforming Process ◽  
Rapid Pace ◽  
Innovative Work ◽  
Ultra High Strength Steels ◽  
Different Characteristics ◽  
Forming Methods

Advanced forming technologies have been evolving at a rapid pace with the products applicability in the industrial fields of aerospace and automobile especially for the materials like aluminum and titanium alloys (light weight) and ultra-high strength steels. Innovative forming methods like hydroforming (tube and sheet) have been proposed for industries throughout the world. The ever-increasing needs of the automotive industry have made hydroforming technology an impetus one for the development and innovations. In this paper, the review on various developments towards lightweight materials for different applications is presented. The influencing process parameters considering the different characteristics of the tube and sheet hydroforming process have also been presented. General ideas and mechanical improvements in sheet and tube hydroforming are given late innovative work exercises. This review will help researchers and industrialists about the history, state of the art in hydroforming technologies of the lightweight materials.

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.

Development of an automotive rear subframe by the tube hydroforming process

2008 ◽  
Vol 222 (11) ◽  
pp. 1977-1984 ◽  
Author(s):  
K J Kim ◽  
S T Won ◽  
Y H Lee ◽  
D S Bae ◽  
C W Sung ◽  
...  
Keyword(s):  
Tube Hydroforming ◽  
High Strength Steels ◽  
High Strength ◽  
Design Stage ◽  
Tube Material ◽  
Cross Sectional ◽  
Whole Process ◽  
Steel Material ◽  
Hydroforming Process ◽  
Efficient Manufacturing

The automotive industry has shown a growing interest in tube hydroforming during recent years. The advantages of hydroforming (less thinning, a more efficient manufacturing process, etc.) can, for instance, be combined with the high strength of extra-high-strength steels, which are usually less formable, to produce structural automotive components which exhibit lower weight and improved service performance. Design and production of tubular components require knowledge about tube material and forming behaviour during hydroforming and how the hydroforming operation itself should be controlled. These issues are studied analytically in the present paper. In this study, the whole process of rear subframe parts development by tube hydroforming using steel material having a tensile strength of 440MPa is presented. At the part design stage, it requires a feasibility study and process design assisted by computer aided engineering to confirm hydroformability in detail. The effects of parameters such as internal pressure, axial feeding, and geometry shape in the automotive rear subframe by the hydroforming process were carefully investigated. The overall possibility of hydroformable rear subframe parts could be examined by cross-sectional analyses. Moreover, it is essential to ensure the formability of tube material on every forming step such as pre-bending and hydroforming. In addition, all the components of a prototyping tool are designed and interference with a press is examined from the point of geometry and thinning.

Hydraulic Bulge Tests of Magnesium Tubes at Elevated Temperatures

2009 ◽  
Vol 83-86 ◽  
pp. 1135-1142 ◽  
Author(s):  
Yeong-Maw Hwang ◽  
H.C. Chuang ◽  
B.J. Chen
Keyword(s):  
Magnesium Alloy ◽  
Elevated Temperatures ◽  
Testing Machine ◽  
Tube Hydroforming ◽  
Tensile Tests ◽  
Biaxial Stress ◽  
Tube Length ◽  
Uniaxial Tensile ◽  
Hydraulic Bulge ◽  
Different Temperatures

Evaluation of the formability of tubes is an important issue in tube hydroforming processes. Since tubular materials during tube hydroforming are under a biaxial even triaxial stress state, other biaxial-stress-based testing methods are needed. In this paper, uniaxial tensile tests at different temperatures are firstly employed to evaluate the material properties of magnesium alloy AZ61 tubes. A hydraulic bulge warm forming machine, which is used for hydraulic bulge tests with a fixed tube length, is also designed and manufactured. Using this self-designed testing machine, experiments of bulge tests of magnesium alloy AZ61 tubes at elevated temperatures are carried out. From the experimental results, the bulge formability of the magnesium alloy tubes at different temperatures is discussed.

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.

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.

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.

scholarly journals Hydroforming Process for an Ultrasmall Bending Radius Elbow

2018 ◽  
Vol 2018 ◽  
pp. 1-15
Author(s):  
Shangwen Ruan ◽  
Lihui Lang ◽  
Yulong Ge
Keyword(s):  
Heat Treatment ◽  
High Performance ◽  
Thickness Distribution ◽  
Tube Hydroforming ◽  
Welding Process ◽  
Forming Process ◽  
Sealing Performance ◽  
Lap Welding ◽  
Hydroforming Process ◽  
Bending Radius

Bent pipes are widely used in automotive, aviation, and aerospace industries for delivering fluids. Parts having small relative bending radiuses are called elbows. However, fabricating a thin-walled elbow part using the simple bending process poses many challenges. One possible way to manufacture elbows is with the stamping-welding process. The major drawbacks of this method include the decline in sealing performance and the addition in weight attributed to the lap welding process. Tube hydroforming (THF) is considered as a feasible solution to these problems. However, the forming process could be quite complex, and multistep forming is necessary. This study investigates the effects of preliminary processes on elbow forming such as bending, partition forming, and heat treatment and presents a high-performance optimized process design to achieve an ultrasmall radius elbow. The effects of multistep forming on the thickness distribution and the heat treatment on the microstructure have been evaluated. The results obtained from simulations show a reasonable agreement with those from the experiments.

Mechanical Behaviour of Ceramic Beads Used as Medium for Hydroforming at Elevated Temperatures

2009 ◽  
Vol 410-411 ◽  
pp. 61-68 ◽  
Author(s):  
Marion Merklein ◽  
Martin Grüner
Keyword(s):  
Granular Material ◽  
Elevated Temperatures ◽  
Exhaust System ◽  
High Strength Steels ◽  
High Strength ◽  
Compression Direction ◽  
High Efficient ◽  
Hydroforming Process ◽  
Ultra High Strength Steels

The need of light weight construction for high efficient vehicles leads to the use of new materials like aluminium and magnesium alloys or high strength and ultra high strength steels. At elevated temperatures the formability of steel increases as the flow stresses decrease. Forming high complex geometries like chassis components or components of the exhaust system of vehicles can be done by hydroforming. The hydroforming process by oils is limited to temperatures of approximately 300 °C and brings disadvantages of possible leakage and fouling. Using granular material like small ceramic beads as medium could be an approach for hydroforming of ultra high strength steels like MS W1200 and CP W800 at temperatures up to 600 °C. The material properties of granular material are in some points similar to solid bodies, in other points similar to liquids. For understanding and simulation of the behaviour of the medium a basic characterisation of ceramic beads with different ball diameters is necessary. Powder mechanics and soil engineering give ideas for experimental setups. For the conversion of these approaches on the one hand the behaviour of the ceramic beads itself has to be characterized, on the other hand the contact between a blank and the beads have to be investigated. For the tests three different kinds of spheres with a diameter between 63 microns and 850 microns are used. In unidirectional compression test compressibility, pressure distribution in compression direction and transversal compression direction and the effect of bead fracture are investigated. The tests are carried out at different compression velocities and for multiple compressions. For determination of friction coefficients between blank and beads and determination of shear stress in bulk under compression a modified Jenike-Shear-Cell for use in universal testing machines with the possibility of hydraulic compression of the beads is built up. The gained data can be used for material modelling in ABAQUS using Mohr-Coulomb or Drucker-Prager model.

Sign in / Sign up

Export Citation Format

Share Document