Forming Rule Construction for Hourglass-Like Tube Hydroforming with Magnesium Alloy

2009 ◽  
Vol 628-629 ◽  
pp. 489-498
Author(s):  
Shen Yung Lin ◽  
C.M. Chang ◽  
Ruey Fang Shyu
Keyword(s):  
Magnesium Alloy ◽  
Material Flow ◽  
Large Strain ◽  
Tube Hydroforming ◽  
Quantitative Prediction ◽  
Hydraulic Pressure ◽  
Data Sets ◽  
Forming Characteristics ◽  
Tube Hydro Forming ◽  
Thickness Variations

The objective of this study is to construct the forming rule for hourglass-like tube with magnesium alloy during hydro-forming and offer the analysis results as a guideline for magnesium alloy forming in industry. AZ31 magnesium alloy circular tube is used as the billet material for hydro-forming with hydraulic pressure as the main forming power combined with the mechanical auxiliary force from the punch to fabricate the hourglass-like tubing products. A finite element based code is utilized to investigate the forming characteristics of hourglass-like tube forming, by changing process parameters such as punch velocity, hydraulic pressure gradient and tool-workpiece interface friction etc. to investigate the material flow of tube filling, wall thickness variations, and stress and strain distributions. And the abductive network is in turn applied to synthesize the data sets obtained from the numerical simulations. Consequently, a quantitative prediction model is developed for the relationships among the process variables, corner radius and minimum tube thickness in the process of hourglass-like tube hydro-forming with magnesium alloy. The results show that proper mechanical force can help material flow, prevent large strain deformation from falling into the area of negative strain hardening rate, enhance the magnesium alloy to become easy in forming and make tube fitting may to be formed successfully.

Influence of Process Parameters on T-Shape Tube HydroForming Characteristics for Magnesium Alloy

2007 ◽  
Vol 364-366 ◽  
pp. 973-979
Author(s):  
Shen Yung Lin ◽  
C.M. Chang ◽  
C.K. Chang
Keyword(s):  
Magnesium Alloy ◽  
Strain Hardening ◽  
Process Parameters ◽  
Material Flow ◽  
Large Strain ◽  
Manufacturing Cost ◽  
Hydraulic Pressure ◽  
Influence Of Process Parameters ◽  
Forming Characteristics ◽  
Strain Hardening Rate

Due to the light weight and electromagnetic interference shielding capabilities in magnesium alloy material, it is widely utilized in 3C electronic components and automobile parts. However, its formability is very poor due to the phenomenon of negative strain hardening rate appearing as the deformation in large strain range, so it is usually formed as die casting or casting styles leads to much scrap, and manufacturing cost is thus increased. The objective of this study is to investigate the effect of process parameters on T-shape tube hydro-forming characteristics for magnesium alloy and it may offer the data resulting from the analysis to predict an acceptable product of tube fitting for magnesium alloy forming in industry. AZ31 magnesium alloy tube is used as the billet material for hydro-forming with hydraulic pressure as the main forming power combined with the mechanical auxiliary force from the punch to fabricate the T-shape tubing products. Finite element code DEFORM-3D is adopted to investigate the forming states of T-shape tube forming, by changing process parameters; such as punch velocity, hydraulic pressure, fillet radius of the die and tool-workpiece interface friction etc. to investigate the material flow of tube fitting, wall thickness variations, and stress and strain distributions. By qualifying the forming processes whether if it is completed or not, and synthesizing the overall analysis and judgment, we establish an admissible level of process parameter range for complete tube manufacture. The results show that suitable mechanical force can help material flow, prevent large strain deformation falling into the area of negative strain hardening rate, enhance magnesium alloy to become easy in forming and make tube fitting to be formed successfully.

Construction of a Prediction Model for an Acceptable T-Shape Tube Product in Magnesium Alloy Hydro-Forming

2010 ◽  
Author(s):  
S. Y. Lin ◽  
C. M. Chang ◽  
R. F. Shyu
Keyword(s):  
Neural Network ◽  
Finite Element ◽  
Magnesium Alloy ◽  
Prediction Model ◽  
Process Parameters ◽  
Wall Thickness ◽  
Hydraulic Pressure ◽  
Tube Forming ◽  
Finite Element Software ◽  
Forming Characteristics

The finite element method in conjunction with abductive neural network is applied to predict an acceptable T-shape product of which the minimum wall thickness and the protrusion height being fulfilled the industrial demand in the magnesium alloy hydro-forming. AZ31 magnesium alloy circular tube is used as the billet material for hydro-forming with hydraulic pressure as the main forming power combined with the mechanically auxiliary force from the punch to fabricate a qualified T-shape tubing product. Finite element software is adopted to investigate the forming characteristics of T-shape tube forming, by changing process parameters such as punch velocity, hydraulic pressure, fillet radius of the die and tool-workpiece interface friction etc. to investigate the material flow of tube forming, and the variations of wall thickness and protrusion height. And the neural network method in turn is applied to synthesize the data sets obtained from the numerical simulations and a prediction model for an acceptable T-shape tube product in magnesium alloy hydro-forming is thus constructed. From the prediction model, a suitable range of the process parameters variation for producing those qualified T-shape tubes that may be accepted in industrial applications can thus be identified.

Grain Structure Formation Ahead of Tool during Friction Stir Welding of AZ31 Magnesium Alloy

2010 ◽  
Vol 160 ◽  
pp. 313-318 ◽  
Author(s):  
Uceu Suhuddin ◽  
Sergey Mironov ◽  
H. Takahashi ◽  
Yutaka S. Sato ◽  
Hiroyuki Kokawa ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Magnesium Alloy ◽  
Structure Formation ◽  
Material Flow ◽  
Boundary Migration ◽  
Deformation Mode ◽  
Grain Structure ◽  
Az31 Magnesium Alloy ◽  
Structure Evolution ◽  
Friction Stir

The “stop-action” technique was employed to study grain structure evolution during friction-stir welding of AZ31 magnesium alloy. The grain structure formation was found to be mainly governed by the combination of the continuous and discontinuous recrystallization but also involved geometric effect of strain and local grain boundary migration. Orientation measurements showed that the deformation mode was very close to the simple shear associated with the rotating pin and material flow arose mainly from basal slip.

The Influence of Die Geometry on the Radial Extrusion Processes with AA 6063 Aluminium Alloy

2006 ◽  
Vol 519-521 ◽  
pp. 937-942
Author(s):  
Dong Hwan Jang ◽  
J.H. Ok ◽  
H.S. Koo ◽  
G.M. Lee ◽  
Beong Bok Hwang
Keyword(s):  
Process Parameters ◽  
Material Flow ◽  
Deformation Pattern ◽  
Relative Deformation ◽  
Die Geometry ◽  
Single Action ◽  
Pressing Process ◽  
Major Process ◽  
Forming Characteristics ◽  
Gap Height

The rigid-plastic finite element method has been applied to three variants of radial extrusion processes to investigate the influence of die geometry on the material flow into the flange gap. Case I involves forcing a cylindrical billet against a flat die, which is a single action pressing process. In case II, another single action pressing process, the upper punch forces a billet against a stationary punch recessed in the lower die. Both the upper and lower punches move together in Case III toward the center of billet at the same speed with a double action tool. Major process parameters are identified as the relative gap height and the die corner radius in constant relative deformation. The relative gap height is defined as the ratio of gap height to billet diameter. Extensive simulation work for various combinations of process parameter value has been performed and then the main characteristics of the deformation patterns of each case are observed to define the terms which represent the forming characteristics of the flange in radial extrusion processes in terms of separation height, asymmetric ratio of height, and asymmetric ratio of angle, respectively. The effect of major process parameters on the material flow into the flange gap has been also analyzed in terms of flange radius and flange angle. The effect of frictional condition on the separation height has been also analyzed to investigate the edge separation of flange from the flat die. AA 6063 aluminum alloy is selected as a model material throughout the analysis. Simple comparison between AA 6063 and AISI 1006 steel has been also made to investigate the effect of material selection on the deformation pattern, especially in terms of separation height in Case I and asymmetry in Case II, respectively.

Large Strain Behaviour of ZEK100 Magnesium Alloy at Various Strain Rates

2015 ◽  
pp. 191-195
Author(s):  
Julie Lévesque ◽  
Srihari Kurukuri ◽  
Raja Mishra ◽  
Michael Worswick ◽  
Kaan Inal
Keyword(s):  
Magnesium Alloy ◽  
Large Strain ◽  
Strain Rates ◽  
Strain Behaviour
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