Integrated Tube and Double Sheet Hydroforming Technology - Optimised Process for the Production of a Complex Part

2007 ◽  
Vol 344 ◽  
pp. 477-484 ◽  
Author(s):  
Manfred Geiger ◽  
Marion Merklein ◽  
Massimo Cojutti
Keyword(s):  
Axial Force ◽  
Process Parameters ◽  
Complex Geometry ◽  
Tube Hydroforming ◽  
Innovative Technology ◽  
Sheet Hydroforming ◽  
Complex Part ◽  
Hydroforming Process ◽  
Hollow Part ◽  
Tubular Component

The possibility to produce lightweight components with a complex geometry enhanced, in the last decades, the industrial application of the tube hydroforming and, more recently and restricted to specific industrial fields, of the sheet hydroforming technology. The integration in one tool of a tube and a double sheet hydroforming process represents an innovative technology which further emphasises the advantages offered by hydroforming in terms of costs reduction and complexity of the manufactured part. This paper describes the design and the construction of a complex hollow part resulting from the simultaneous hydroforming of two sheets and a tubular component in one tool. The focus is set in particular on the optimisation of the joining zone between tube and sheet pair, whose geometry allows a “metallic” sealing of the gap between the sheets and the tube, i.e. without using sealing components. The contact between tube and sheet pair allows the transmission of the axial force used to support the bulging of the tube to the sheet blanks, thus increasing their draw-in in the die and, consequently, avoiding the occurrence of tearing on the part. The paper describes the optimisation of different process parameters like the shape and the dimension of the blanks, their initial positioning in the tool, the value of the axial force applied to the tubular component and the blankholder force during the preforming and the calibrating stages.

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 – 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.

The Effect of Polyurethane Hardness on the New Die-Set of Sheet Hydroforming Process Parameters

2012 ◽  
Vol 152-154 ◽  
pp. 1623-1627
Author(s):  
Morteza Hosseinzadeh
Keyword(s):  
Process Parameters ◽  
Thickness Distribution ◽  
Effective Parameters ◽  
Blank Holder Force ◽  
Blank Holder ◽  
Sheet Hydroforming ◽  
Die Set ◽  
Hydroforming Process

In recent years, several sheet hydroforming methods have been introduced by researchers. Despite the advantages of these methods, they have some limitations. The author [1] already proposed a novel sheet hydroforming method that is a combination of the standard and hydromechanical sheet hydroforming processes. The proposed method has the advantages of both processes and eliminates their limitations. In this method, a polyurethane diaphragm was used as a part of die-set to control the blank holder force. In this paper, the effect of polyurethane hardness on the effective parameters of the combined sheet hydroforming die-set such as forming pressure, thickness distribution of formed cup and maximum thinning zone of formed cup was investigated experimentally. It was shown that a softer polyurethane needs to a higher oil pressure to prevent wrinkling in the flange of the part. And tearing occurs at higher level of forming pressure. Also it was shown that by softer polyurethane, better thickness distribution was obtained.

Buckling of Tube for Tube Hydroforging

2019 ◽  
Author(s):  
Chetan P. Nikhare
Keyword(s):  
Axial Force ◽  
Thickness Distribution ◽  
Fluid Pressure ◽  
Tube Hydroforming ◽  
Expansion Ratio ◽  
Rigid Bodies ◽  
Maximum Expansion ◽  
Tube Forming ◽  
Strain Pattern ◽  
Hydroforming Process

Abstract Tube forming is one of the most common manufacturing processes to shape the tubes. Within tube forming operations the general practice is to expand and reduce the tube end cross-section and bend the tube by means of a solid mandrel. Mostly the mandrel is rigid bodies. To reduce the friction between the tube and the tool, tube hydroforming process was evolved in which the fluid was highly pressurized to expand the tube shape to the desired shape. By reducing the friction more uniform thickness could be achieved and thus increase in formability. In this paper, the tube was formed in two steps with low fluid pressure and axial force. The tube will be allowed to a useful maximum buckle by applying the axial force and/or a ramp internal pressure which then hydroforged with constant pressure for the maximum expansion ratio. The buckling mechanics of tube with respect to the fluid pressure and the axial force was studied. Further, the pressure requirement for hydroforging was investigated with respect to the length of the tube. The strain pattern and thickness distribution were studied in the buckling/bulging and hydroforging step.

Investigation of Hydroforming Technology for Manufacturing an Auto Complex Part

2019 ◽  
Vol 957 ◽  
pp. 138-147
Author(s):  
Viorel Paunoiu ◽  
Florian Pereira ◽  
Virgil Gabriel Teodor ◽  
Catalina Maier
Keyword(s):  
Experimental Data ◽  
Numerical Model ◽  
Rubber Membrane ◽  
Sheet Hydroforming ◽  
Part Geometry ◽  
Complex Part ◽  
Experimental Tool ◽  
Hydroforming Process ◽  
Simulation Results ◽  
Auto Part

Hydroforming process is used for obtaining different kinds of sheet metal components in an economic manner in terms of time and costs reduction and increase of the product quality. This paper deals with the application of this type of technology for manufacturing a rotational auto part from aluminium alloy. An experimental tool for hydroforming with rubber membrane was used. A set of dies with different geometries has been designed and constructed. Experiments have been conducted for investigation the ability of transferring features from the die onto the blank surface for different die geometries and pressures. The hydroformed part was measured using CMM. Based on the experimental data a numerical model was designed. FEM using Abaqus solver was used for investigated the part geometry and the effective stress distribution under various pressures conditions and dies geometries. The experimental and simulation results show the feasibility of applying the sheet hydroforming process in order to obtain a sound product.

scholarly journals Effect of input variables uncertainty in free tube hydroforming process

2021 ◽  
Author(s):  
Ali Khalfallah ◽  
Pedro André Prates ◽  
José Valdemar Fernandes
Keyword(s):  
Strain Hardening ◽  
Response Surface ◽  
Process Parameters ◽  
Tube Hydroforming ◽  
Response Surface Model ◽  
Bursting Pressure ◽  
Strain Hardening Exponent ◽  
Surface Model ◽  
Significant Variable ◽  
Hydroforming Process

Tube hydroforming (THF) is a plastic forming process that uses tubes with an initial circular cross section, in which pressurized fluid and axial feeds are applied for producing parts with various cross-sectional shapes. Despite of the complexity of THF process, a great progress in the automotive and aerospace industry has been made due to its advantages, such as, consolidation and weight reduction over conventional stamped and welded parts. The analysis of THF process is typically based on deterministic approaches, excluding scattering effects that influence the process reliability. Thus, robust design of tube hydroforming aims to vanish noise factors effects on process responses by considering the influence of process parameters variability. If this fluctuation is not monitored, then the fluctuation of the hydroformed parts quality may contribute to high scrap rates. In this work, the influence of variability in the THF material and process parameters (e.g. yield stress, strength coefficient, strain hardening exponent, plastic anisotropy, initial tube thickness and bulged length) on the bursting pressure is analyzed resorting to a response surface model. The statistically significant variables, which mostly influence the free bulge hydroforming process, are identified through an analysis of variance. Assuming that the input parameters variability follows the normal distribution, the probability distribution of the bursting pressure is evaluated by involving random process variables into the built response surface model. It was shown that the initial tube thickness is the most statistically significant variable, whereas the strain hardening exponent is the least statistically significant variable.

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.

A Finite Element Model for Hydroforming Parts With Rigid Tolerances

1996 ◽  
Author(s):  
Jian An ◽  
A. H. Soni
Keyword(s):  
Finite Element ◽  
Simulation Model ◽  
Axial Force ◽  
Process Parameters ◽  
Fluid Pressure ◽  
Three Dimensional ◽  
Element Model ◽  
Tubular Part ◽  
Die Profile ◽  
Hydroforming Process

Abstract For many key process parameters in such a hydroforming hole piercing operation, the fluid pressure and the piercing force might be the most important process parameters that determine a quality of hydroformed parts. However, designing such process parameters is still arrived at based on extensive trial-and-error activities and experiences. This situation prevents the hydroforming technology from being adopted further even though the benefits of using hydroforming as an alternative to the conventional stamping is obvious. In this study a finite element based simulation model is developed to investigate the effects of process parameters in a tubular part hydroforming process. The process parameters includes fluid pressure path and axial force path and the curvature of die profile. A simulation model developed for the study is based on an explicit nonlinear finite element code and includes three dimensional modeling of die, blank tube and hole piercing punch. The behaviors of the fluid pressure, axial force and die profiles on the deformation of a complex tubular part are predicted and the design of such process variables is achieved.

Multi-Objective Optimization of the Loading Path in Tube Hydroforming Process Using NCGA

2012 ◽  
Vol 217-219 ◽  
pp. 1885-1889 ◽  
Author(s):  
Zai Xiang Zheng ◽  
Jing Xu ◽  
Hui Shen
Keyword(s):  
Process Parameters ◽  
Optimization Design ◽  
Tube Hydroforming ◽  
Simulation Method ◽  
New Method ◽  
Loading Path ◽  
Instrument Panel ◽  
Pareto Optimum ◽  
Hydroforming Process ◽  
Trial And Error Method

According to the limitations of conventional method of optimization design for the process parameters in the hydroforming process, a new simulation method has been proposed for the optimization of the process parameters, which is the integration of the neighborhood cultivation genetic algorithm (NCGA) and the dynamic explicit algorithm based on finite element method (FEM). The new method has been adopted for the optimization of the hydroforming loading path of an instrument panel beam and the process parameters are the internal pressure vs. time and the axial feeding displacement vs. time. It is concluded that the acquired loading path through the new method is more optimal than the one through the trial and error method. In addition, the new method can simultaneously generate multiple Pareto-optimum solutions in one computation and provide more freedom for the designer's decision making of the process parameters.

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