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.

Research on Wrinkling Behavior in Tube Hydroforming with Axial Feeding

2014 ◽  
Vol 622-623 ◽  
pp. 739-746
Author(s):  
Zhu Lin Hu ◽  
Lian Fa Yang ◽  
Yu Lin He
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
Metal Forming ◽  
Shape Change ◽  
Tube Hydroforming ◽  
Loading Path ◽  
Axial Feeding ◽  
Loading Paths ◽  
Element Simulation

Tube hydroforming (THF) is one of metal forming technologies which has been widely used to manufacture complex hollow workpeices. In THF, a variety of failures may occur and one of them is wrinkling. But recent researches show that wrinkling may be used as a preforming process to improve the formability of tubes. In this paper, a new geometry-based wrinkling indicator is proposed to evaluate the wrinkling level in THF and the wrinkle evolution diagram (WED) based on the shape change of the wrinkles is presented to display the four-stage evolution of the useful wrinkles. The wrinkling levels in THF with axial feeding under various loading paths are predicted respectively via finite element simulation, the influence of loading paths on the wrinkling behavior is investigated, and the evolving stages of the useful wrinkles is revealed via the proposed WED. The results indicate that the proposed wrinkle indicator can distinctly evaluate the wrinkling level, the wrinkling level under pulsating loading path is higher than that under polygonal linear one and four-stage evolution of the useful wrinkles could be evidently demonstrated via the WED. Notation

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.

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.

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.

Friction tests in tube hydroforming

2005 ◽  
Vol 219 (8) ◽  
pp. 587-593 ◽  
Author(s):  
Yeong-Maw Hwang ◽  
Li-Shan Huang
Keyword(s):  
Internal Pressure ◽  
Coefficient Of Friction ◽  
Tube Hydroforming ◽  
Test Method ◽  
Experimental Results ◽  
Friction Test ◽  
Friction Forces ◽  
Axial Feeding ◽  
The Coefficient Of Friction ◽  
Friction Test Method

The objective of this paper is to propose a friction test method to evaluate the performance of different kinds of lubricants and determine their coefficients of friction in tube hydroforming processes. A self-designed apparatus is used to conduct the experiments of friction tests. The coefficient of friction between the tube and the die at the guiding zone is determined. The effects of the internal pressure and the axial feeding velocity on the friction forces and coefficients of friction for various lubricants are discussed. From the experimental results, it is known that MoS2 corresponding to a coefficient of friction of 0.018 is the best lubricant among the evaluated lubricants during tube hydroforming processes.

scholarly journals Numerical Study of Tube Hydroforming Process Using Conical Dies

2021 ◽  
Vol 28 (4) ◽  
pp. 25-36
Author(s):  
Tahseen T. Othman Al-Qahwaji ◽  
Ahmad Ameen Hussain
Keyword(s):  
Numerical Study ◽  
Cone Angle ◽  
Fluid Pressure ◽  
Tube Diameter ◽  
Tube Length ◽  
Thin Wall ◽  
Axial Feeding ◽  
Loading Paths ◽  
Wall Thinning ◽  
Corner Filling

   In this paper the effect of die angle, fluid pressure and axial force on loading paths were studied. In order to reduce the cost and time for the experimental work, ANSYS program is used for implementing the Finite Element Method (FEM), to get optimized loading paths to form a tube using double – cones shape die. Three double die angles θ (116˚ 126˚, 136˚), with three different values of tube outer diametres (40, 45, 50) mm were used. The tube length L_o and thickness t_o for all samples were 80 mm and 2 mm respectively.    The most important results and conclusions that have been reached that had the highest wall thinning percentage of 26.8% with less corner filling is at tube diameter 40 mm and cone angle of (116^°) at forming pressure of 43 MPa with axial feeding 10 mm. However, the lowest wall thinning percentage was 6.9% with best corner filling at diameter 50 mm and cone were angle of (136^°) and forming pressure of 30 MPa with axial feeding 4.5 mm. Two wrinkles constituted during the initial stages of forming the tube with initial diameter of 40 mm where the ratio  d⁄(t=20)   (thick-walled tubes) for all die angles, while only one wrinkle is formed at the center for tubes diameter 45 and 50 mm (thin-walled tubes) . The difference in the location and number of wrinkles at the first stage of formation depends on the loading paths that has been chosen for each process, which was at the diameter 45 and 50 mm towards thin-wall cylinder deformation mode was uniaxial tension. The maximum wall thinning percentage was at the bulge apex for tube diameter 40 mm. But, the maximum wall thinning for tubes of diameters 45 and 50 mm was found at the two sides of the bulge apex .

Optimization for Loading Paths of Tube Hydroforming Using a Hybrid Method

2009 ◽  
Vol 24 (6) ◽  
pp. 700-708 ◽  
Author(s):  
Zhang Yong ◽  
Luen Chow Chan ◽  
Wang Chunguang ◽  
Wu Pei
Keyword(s):  
Hybrid Method ◽  
Tube Hydroforming ◽  
Loading Paths

The Failure Window Method and Its Application in Pipeline Burst

2017 ◽  
Vol 139 (5) ◽  
Author(s):  
Zhanfeng Chen ◽  
Hao Ye ◽  
Sunting Yan ◽  
Xiaoli Shen ◽  
Zhijiang Jin
Keyword(s):  
Internal Pressure ◽  
Maximum Stress ◽  
Oil And Gas ◽  
Maximum Shear Stress ◽  
High Accuracy ◽  
Burst Pressure ◽  
Empirical Equations ◽  
Integrity Assessment ◽  
Wall Thinning ◽  
Window Method

Accurate prediction of the burst pressure is indispensible for the engineering design and integrity assessment of the oil and gas pipelines. A plenty of analytical and empirical equations have been proposed to predict the burst pressures of the pipelines; however, it is difficult to accurately predict the burst pressures and evaluate the accuracy of these equations. In this paper, a failure window method was presented to predict the burst pressure of the pipes. First, the security of the steel pipelines under the internal pressure can be assessed. And then the accuracy of the previous analytical and empirical equations can also be generally evaluated. Finally, the effect of the wall thinning of the pipes on the failure window was systemically investigated. The results indicate that it is extremely formidable to establish an equation to predict the burst pressure with a high accuracy and a broad application, while it is feasible to create a failure window to determine the range of the dangerous internal pressure. Calculations reveal that some predictions of the burst pressure equations like Faupel, Soderberg, Maximum stress, and Nadai (1) are overestimated to some extent; some like ASME, maximum shear stress, Turner, Klever and Zhu–Leis and Baily–Nadai (2) basically reliable; the rest like API and Nadai (3) slightly conservative. With the wall thinning of the steel pipelines, the failure window is gradually lowered and narrowed.

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