The Hydroforming of Micro-Square Tubes With Non-Equal Section and Dendritic Shape

2006 ◽  
Vol 505-507 ◽  
pp. 739-744
Author(s):  
Yuan Chuan Hsu ◽  
Tung Sheng Yang ◽  
J.L. Wu ◽  
Y.X. Chen
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
Tube Hydroforming ◽  
Simulation Technique ◽  
Hydraulic Pressure ◽  
Micro Forming ◽  
Wall Thinning ◽  
Element Simulation ◽  
Feeding Speed ◽  
Dendritic Shape

Currently, tube hydroforming and metal micro-forming technique have emerged as the attractive and important developing tendencies in industry. Hence, in this study, the finite element simulation technique was employed to investigate the micro-hydroforming for making the micro-square tube with non-equal section and dendritic shape from square tube. Results of the current study show that the deformation of micro-square tube can be effectively analyzed by finite element simulation. The bulging and wall thinning of the tube are severely influenced not only by the internal hydraulic pressure but also by the punch axial feeding speed.

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

Finite Element Simulation Technique for Evaluation of Opening Stresses Under High Plasticity

2020 ◽  
Author(s):  
Ans Al Rashid ◽  
Ramsha Imran ◽  
Muhammad Yasir Khalid
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Fatigue Life ◽  
Mechanical Behavior ◽  
Finite Element Simulation ◽  
Simulation Technique ◽  
High Plasticity ◽  
Element Analysis ◽  
Element Simulation ◽  
Stress Levels

Abstract The mechanical behavior of materials plays a vital role in the structural performance of designed structures. Therefore, significant resources are devoted globally towards experimental characterization of material behavior, especially for the experiments requiring particular protocols. Contrary, finite element analysis tools have made a substantial contribution to the design of structural elements, which could conserve a significant amount of resources and material wastage. Evaluation of fatigue life of materials is necessary to predict the life expectancy of the structures precisely, and opening stress levels under fatigue loading contributes towards this evaluation. Railways serve as freight and passenger carrier transportation modes. The railway axles contribute as the primary load-carrying element; therefore, the design of railway axles and the study of their mechanical behavior under repeated loading is vital. In this study, the authors present a finite element simulation technique to evaluate the opening stress levels for two structural steels subjected to low cycle fatigue. The finite element analysis (FEA) model was designed and validated following the simulation of fatigue crack propagation under high plasticity conditions. Numerical simulation results were compared with the experimental results obtained earlier through the digital image correlation (DIC) technique. To conclude, FEA could be a useful tool to predict crack closure phenomena and, ultimately, the fatigue life of components. However, researchers need to establish more sophisticated numerical tools for more precise results in case of high plasticity conditions near the crack tip.

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.

Finite Element Simulation of Backward Micro Extrusion for Annealed Copper

2018 ◽  
Author(s):  
Md Mosleh Uddin ◽  
Debabrata Mondal ◽  
Paul D. Herrington
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
Extrusion Process ◽  
Simulation Software ◽  
Uniaxial Compression Test ◽  
Micro Forming ◽  
Element Simulation ◽  
Micro Parts ◽  
Annealed Copper ◽  
Bulk Production

The growing demand of miniaturized products is tremendously influencing the progress of micro-forming technologies. The implementations of micro technologies in the field of microelectronics, sensors, and medical equipment necessitate versatile micro-forming processes. These processes facilitate the bulk production of micro parts with higher precision, minimum material waste, and better surface finish. However, micro-forming technologies are still expensive due to the limitations of traditional materials and stringent size requirements. Finite element simulations are being widely used to analyze the manufacturing process parameters before going into production. In this research, a backward micro-extrusion process is simulated for annealed copper by using commercial Finite element simulation software. The effects of different punch diameters, friction coefficients, punch velocities on the load-displacement curves and the resulting strain distributions are investigated. To overcome limitations of the post-yield hardening data from the uniaxial compression test, the Ramberg-Osgood model is proposed to predict the responses at the higher plastic strain.

Finite Element Simulation for Superplastic Blow Forming of Toroidal Ti-6Al-4V Fuel Tank

2012 ◽  
Vol 735 ◽  
pp. 240-245 ◽  
Author(s):  
Jong Hoon Yoon ◽  
Ho Sung Lee ◽  
Yeng Moo Yi ◽  
Joon Tae Yoo
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
Thickness Distribution ◽  
Pressure Profile ◽  
Fuel Tank ◽  
Hydraulic Pressure ◽  
Final Shape ◽  
Element Simulation

In the current study, the finite element simulation for superplastic blow forming of a toroidal Ti-6Al-4V fuel tank is discussed. 3 types of preforms are investigated in order to obtain defect free final shape with desirable thickness distribution. From the simulation result, forming tool is designed so that the hydraulic pressure is not used. The forming test is carried out using forming pressure profile obtained from the simulation, and the validity of the selected perform is investigated in terms of thickness distribution and deformed shape.

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