Punch Radius Influence on “Large Size” Hydroformed Components

2012 ◽  
Vol 504-506 ◽  
pp. 937-942
Author(s):  
Gabriele Papadia ◽  
Antonio del Prete ◽  
Alessandro Spagnolo
Keyword(s):  
Sheet Metal ◽  
Process Parameters ◽  
Process Design ◽  
Numerical Study ◽  
Fluid Pressure ◽  
Large Size ◽  
Blank Sheet ◽  
Punch Radius ◽  
Hydroforming Process ◽  
Compressed Fluid

Sheet metal hydroforming has gained increasing interest during last years, especially as application in the manufacturing of some components for: automotive, aerospace and electrical appliances for niche productions. Different studies have been also done to determine the optimal forming parameters making an extensive use of FEA. In the hydroforming process a blank sheet metal is formed through the action of a fluid and a punch. It forces the sheet into a die, which contains a compressed fluid. Many studies have been focused on the analysis of process and geometric parameters influence about the hydroforming process of a single product with main dimensions till to 100 mm. In this paper the authors describe the results of an experimental activity developed on two different large sized products obtained through sheet metal hydroforming. Different geometric and process parameters have been taken into account during the testing phase to study, in particular, the punch radius influence on the process feasibility. An ANOVA analysis has been implemented to study the influence of geometrical and process parameters on the maximum hydroforming depth. Through this work it has been possible to verify that in the hydroforming process of large size products geometry and, in particular, punch radius, are some of the main factors that influences the feasibility of the products. Different considerations can be made about the effects of the blankholder force and the fluid pressure on the maximum hydroforming depth. As further developments, the authors would perform a numerical study in order to enlarge the knowledge of the process design space to other possible values of the punch radius.

A Critical Review of Tube and Sheet Metal Hydroforming Technology

1996 ◽  
Author(s):  
Jian An ◽  
A. H. Soni
Keyword(s):  
Sheet Metal ◽  
Thickness Distribution ◽  
Fluid Pressure ◽  
Point Of View ◽  
Parameter Design ◽  
Back Side ◽  
Part Quality ◽  
Element Simulation ◽  
Part Surface ◽  
Hydroforming Process

Abstract The hydroforming technology, which is rapidly gaining popularity in the sheet metal and tube forming industry is reviewed. The features and the characteristics of the hydroforming process are described. The uniformly distributed fluid pressure covers the back side of the sheet as a die generates many advantages in the technical point of view as improving the part surface quality, reducing the forming severity and smoothing the thickness distribution. The benefits of using hydroforming technology are examined and analyzed in a technical level. The better part quality, less cost of tooling, materials saving and part weight reduction can be achieved using the hydroforming technology. The design methodologies for the hydroforming process parameters are reviewed and discussed in a certain detail. Computer-aided-engineering such as finite element simulation is suggested for such process parameter design.

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

An Experimental and Numerical Study to Analysis and Design of Sheet Hydroforming Process for an Automobile Fender Shell

2006 ◽  
Author(s):  
Mohammad Habibi Parsa ◽  
Payam Darbandi
Keyword(s):  
Finite Element ◽  
Numerical Study ◽  
Fluid Pressure ◽  
Finite Element Program ◽  
New Approach ◽  
Explicit Finite Element ◽  
Sheet Hydroforming ◽  
Analysis And Design ◽  
Hydroforming Process ◽  
Element Program

A new approach for manufacturing of shell fender is proposed and has been examined numerically and experimentally. The new suggested method is based on sheet hydroforming process, which has a lot of advantages over conventional deep drawing process. After defining the shape of initial blank using an inverse finite element program, numerical evaluation of the proposed sheet hydroforming process for production of shell fender has been carried out using an explicit finite element code considering fluid pressure, boundary conditions and tools. Then experimental evaluation has been carried out using down sized specimen and the results have been compared with results of previous simulations. It has been shown that there are similar trends between finite element and experimental results.

Theoretical and Experimental Analysis of Failure for the Hemisphere Punch Hydroforming Processes

1996 ◽  
Vol 118 (3) ◽  
pp. 434-438 ◽  
Author(s):  
Tze-Chi Hsu ◽  
Shian-Jiann Hsieh
Keyword(s):  
Experimental Data ◽  
Limit Theorem ◽  
Sheet Metal ◽  
Lower Bounds ◽  
Yield Criterion ◽  
Fluid Pressure ◽  
Upper And Lower Bounds ◽  
Premature Failure ◽  
Hydroforming Process ◽  
Theoretical Results

A limit theorem of plasticity has been developed to investigate the hemisphere punch hydroforming process. The limit theorem of plasticity is used to predict the upper and lower bounds of the permissible fluid pressure. Loci representing the critical fluid pressures which result in the rupture and wrinkling are presented. The property of the sheet metal is governed by Hill’s quadratic yield criterion with a power-law hardening for anisotropic material. The premature failure is avoidable if the fluid pressure path is restricted to travel only within the suggested bounds. The theoretical results which include the failure prediction and wrinkling distribution are verified by conducting a serial of hydroforming experiments. The experimental data agrees well with the computed results and demonstrates the technological usefulness of the results.

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.

An Experimental and Numerical Study of Dieless Water Jet Incremental Microforming

2019 ◽  
Vol 141 (4) ◽  
Author(s):  
Yi Shi ◽  
Weizhao Zhang ◽  
Jian Cao ◽  
Kornel F. Ehmann
Keyword(s):  
Numerical Model ◽  
Sheet Metal ◽  
Process Parameters ◽  
High Speed ◽  
Tool Path ◽  
Numerical Study ◽  
Single Point ◽  
Thin Sheet ◽  
Water Jet ◽  
Truncated Cone

Conventional single-point incremental forming (SPIF) is already in use for small batch prototyping and fabrication of customized parts from thin sheet metal blanks by inducing plastic deformation with a rigid round-tip tool. The major advantages of the SPIF process are its high flexibility and die-free nature. In lieu of employing a rigid tool to incrementally form the sheet metal, a high-speed water jet as an alternative was proposed as the forming tool. Since there is no tool-workpiece contact in this process, unlike in the traditional SPIF process, no lubricant and rotational motion of the tool are required to reduce friction. However, the geometry of the part formed by water jet incremental microforming (WJIMF) will no longer be controlled by the motion of the rigid tool. On the contrary, process parameters such as water jet pressure, stage motion speed, water jet diameter, blank thickness, and tool path design will determine the final shape of the workpiece. This paper experimentally studies the influence of the above-mentioned key process parameters on the geometry of a truncated cone shape and on the corresponding surface quality. A numerical model is proposed to predict the shape of the truncated cone part after WJIMF with given input process parameters. The results prove that the formed part's geometric properties predicted by the numerical model are in excellent agreement with the actually measured ones. Arrays of miniature dots, channels, two-level truncated cones, and letters were also successfully fabricated on stainless-steel foils to demonstrate WJIMF capabilities.

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.

Influence of Process Parameters on the Deep Cup-Drawing Process by Simulation

2012 ◽  
Vol 430-432 ◽  
pp. 1107-1110
Author(s):  
Xiao Bing Zhang ◽  
Xiao Hui Jiang
Keyword(s):  
Sheet Metal ◽  
Process Parameters ◽  
Influence Factor ◽  
Deformation Behaviour ◽  
Forming Process ◽  
Minimum Thickness ◽  
Influence Of Process Parameters ◽  
Danger Zone ◽  
Blank Sheet ◽  
Cup Drawing

Cup drawing, besides its importance as forming process, also serves as a basic test for the sheet metal formability. To determine the optimum values of the process parameters, it is essential to find their influence on the deformation behaviour of the sheet metal. Based on the predicted thickness and stress distribution of the deep drawn circular cup and analysis of process parameters by LS-DYNA software in the paper, it is evident that the minimum thickness is at the punch radius, which was the danger zone for breaking. BHF is the main influence factor of a axi-symmetric cup, according drawing theory, the curve of the variable blankholder force (VBHF) we designed could improve the formability of sheet. Further, it is shown mold radius has the greater influence on the deep drawing of blank sheet.

Analysis of Tee Pipe Hydroforming Process Parameters

2014 ◽  
Vol 651-653 ◽  
pp. 643-646
Author(s):  
Shi Gang Wang ◽  
Dan Wang ◽  
Fu Sheng Gao
Keyword(s):  
Finite Element ◽  
Process Parameters ◽  
Process Design ◽  
Reference Data ◽  
Initial Length ◽  
Forming Force ◽  
Extrusion Speed ◽  
Finite Element Software ◽  
Actual Production ◽  
Hydroforming Process

By using the finite element software Dynaform, the process of tee pipe hydroforming is obtained with the analysis of forming force, the extrusion speed, die radius, friction conditions and the initial length of tube rounds, which are key process parameters on the influence of tee pipe. Obtained by analyzing the tee pipe hydroforming law, to the actual production of tee pipe hydroforming process design provides the reference data and related guidance.

scholarly journals On Hydromechanical Interaction during Propagation of Localized Damage in Rocks

Minerals ◽  
2021 ◽  
Vol 11 (2) ◽  
pp. 162
Author(s):  
A.A. Jameei ◽  
S. Pietruszczak
Keyword(s):  
Numerical Study ◽  
Fluid Pressure ◽  
Implicit Time ◽  
Integration Scheme ◽  
Internal Length ◽  
Element Analysis ◽  
Equivalent Permeability ◽  
Mechanical Coupling ◽  
Splitting Test ◽  
Localized Damage

This paper provides a mathematical description of hydromechanical coupling associated with propagation of localized damage. The framework incorporates an embedded discontinuity approach and addresses the assessment of both hydraulic and mechanical properties in the region intercepted by a fracture. Within this approach, an internal length scale parameter is explicitly employed in the definition of equivalent permeability as well as the tangential stiffness operators. The effect of the progressive evolution of damage on the hydro-mechanical coupling is examined and an evolution law is derived governing the variation of equivalent permeability with the continuing deformation. The framework is verified by a numerical study involving 3D simulation of an axial splitting test carried out on a saturated sample under displacement and fluid pressure-controlled conditions. The finite element analysis incorporates the Polynomial-Pressure-Projection (PPP) stabilization technique and a fully implicit time integration scheme.

Sign in / Sign up

Export Citation Format

Share Document