Investigation on the Formability of a Tube in Pulsating Hydroforming

2009 ◽  
Vol 628-629 ◽  
pp. 617-622 ◽  
Author(s):  
Lian Fa Yang ◽  
Feng Jun Chen
Keyword(s):  
Finite Element ◽  
Internal Pressure ◽  
Wall Thickness ◽  
Thickness Distribution ◽  
Forming Process ◽  
Element Analysis ◽  
Thickness Uniformity ◽  
Die Filling ◽  
Filling Ability ◽  
T Values

Based on the finite element simulation of tube-hydroforming process with pulsating internal pressure, the influence of the pressure increment p and the time increment t of the pulsating pressure upon the formability of a tube have been investigated by analyzing and comparing the four formability indicators such as thickness distribution, die-filling ability, wall thickness uniformity and potential fracturing. A new indicator f is proposed to estimate the formability of a tube on the basis of the finite element analysis (FEA). The results show that: the indicator f can reasonably reflect the combination formability of a tube in hydroforming including the die-filling ability, the wall-thickness uniformity and the deformation reliability; the p and t values have different influence on the four formability indicators as mentioned above; the smaller the p and t values or the more the internal pressure pulsates during the forming process, the better the combination formability of the tube would be.

Shell Element Formulation Based Finite Element Modeling, Analysis and Experimental Validation of Incremental Sheet Forming Process

2015 ◽  
Author(s):  
Govind N. Sahu ◽  
Sumit Saxena ◽  
Prashant K. Jain ◽  
J. J. Roy ◽  
M. K. Samal ◽  
...  
Keyword(s):  
Finite Element ◽  
Thickness Distribution ◽  
Shell Element ◽  
Time Profile ◽  
Experimental Results ◽  
Computational Time ◽  
Element Formulation ◽  
Forming Process ◽  
Element Analysis ◽  
Shell Elements

This paper presents the effect of shell element formulations on the response parameters of incremental sheet metal forming process. In this work, computational time, profile prediction and thickness distribution are investigated by both finite element analysis and experimentally. The experimental results show that the thickness distribution is in good agreement with the results obtained with Belytschko-Tsay (BT) and Improved Flanagan-Belytschko (IFB) shell element formulations. These two shell element formulations do trade-off between computational time and accuracy. For more accurate results, the BT shell element formulation is better and for less computational time with good results, the IFB shell element is preferable. Finally, BT shell element formulation has been chosen for FE Analysis of ISF process in HyperWorks, since the results of thickness distribution and profile prediction is in better agreement with the experimental results as well as the computational time is less among the shell elements.

A Study on the Large-Diameter Seamless Gas Cylinder Dimensional Accuracy of Rotary Expanding Process with Finite Element Analysis

2011 ◽  
Vol 328-330 ◽  
pp. 136-142
Author(s):  
Shun Yao Jin ◽  
Zhong Guo Huang ◽  
Zong Ke Shao ◽  
Ming Xiang Li ◽  
Hui Lai Sun ◽  
...  
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Wall Thickness ◽  
Large Diameter ◽  
Dimensional Accuracy ◽  
Steel Tube ◽  
Element Analysis ◽  
Thickness Uniformity ◽  
Gas Cylinder ◽  
Roll Gap

This paper expounds the application of rotary expanding process to manufacture the large-diameter hot-rolled seamless gas cylinder. Through analytic geometry method, an equation is established among the tail roll gap, roll distance and the plug protrusion distance. 3D drawing software CATIA-V5 is applied to build 3d models of steel tube and rolling tools. The rolling process is simulated by MSC.Marc FEA (finite element analysis) software. Marc’s second development function and FORTRAN software’s extracting finite element node coordinates function are applied to calculate the wall thickness uniformity. A novel method to calculate the wall thickness uniformity after finite element analysis is proposed. The wall thickness uniformity of steel tube after rolling is well simulated and compared by MSC.Marc FEA software, which can help the technologist to predict and choose the best rolling parameter. For gas cylinder rolling, the tail roll gap should be set to 17mm. The roller distance and the plug protrusion distance should be set as 342mm and 78mm separately.

Three Dimensional Finite Element Analysis on Neck-Spinning Process of Thick-Walled Tube at an Elevated Temperature

2012 ◽  
Vol 579 ◽  
pp. 269-277 ◽  
Author(s):  
Chi Chen Huang ◽  
Hsin Yen Fan ◽  
Ching Hua Hung ◽  
Jung Chung Hung ◽  
Chia Rung Lin
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Elevated Temperature ◽  
Thickness Distribution ◽  
Forming Process ◽  
Outer Contour ◽  
Tube Spinning ◽  
Element Analysis ◽  
Spinning Process ◽  
Simulation Results

Tube spinning is a metal forming process used to manufacture axisymmetric products. This study chose a seamless thick-walled steel tube to manufacture a high pressure vessel. Finite element analysis was successfully applied to the neck-spinning process of a thin-walled tube; however, previous research has not investigated the neck-spinning process of thick-walled tubes. Therefore, the aim of this research was to investigate numerically the neck-spinning process of thick-walled tubes at an elevated temperature. The commercial software Abaqus/Explicit was adopted in the simulation. This paper compares experimental and simulation results on thickness distribution and outer contour of the spun tube. During the final stage, the average deviations between the simulation and experiment were 6.74% in thickness and 4.97% in outer contour. The simulation results correspond with those derived in the experiment.

scholarly journals Numerical Study of The Effect of Wall Thickness and Internal Pressure on Von Mises Stress and Safety Factor of Thin-Walled Cylinder for Rocket Motor Case

2020 ◽  
Vol 9 (1) ◽  
Author(s):  
Lasinta Ari Nendra Wibawa
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Internal Pressure ◽  
Wall Thickness ◽  
Axial Stress ◽  
Rocket Motor ◽  
Von Mises Stress ◽  
Element Analysis ◽  
Maximum Hoop Stress ◽  
Von Mises

The rocket motor is an important part of rockets. The rocket motor works using the pressure vessel principle because it works in an environment with high pressure and temperature. This paper investigates the von Mises stress that occurs in thin-walled cylinders and safety factors for rocket motor cases due to the influence of the wall thickness and internal pressure. Dimensions of the cylinder length are 500 mm, outer diameter is 200 mm, and cap thickness is 30 mm. The wall thickness is varied 6, 7, 8, and 9 mm, while the internal pressure is varied 8, 9, and 10 MPa. Stress analysis is performed using the finite element method with Ansys Workbench 2019 R3 software. The simulation results show that the maximum von Mises stress decreases with increasing wall thickness. The maximum von Mises stress increases with increasing internal pressure. The material has a safety factor higher than 1.25 for all variations in wall thickness and internal pressure. It means that the material can withstand static loads. The verification process is done by comparing the results of finite element analysis with analytical calculations for maximum hoop stress and maximum axial stress with a fixed boundary condition. The results of maximum hoop stress and maximum axial stress using finite element analysis and analytical calculations are not significantly different. The percentage of errors between analytical calculations and finite element analysis is less than 6 percent.

A Study on Rotary Expanding Process of Large-Diameter Hot-Rolled Seamless Gas Cylinder with Finite Element Analysis

2011 ◽  
Vol 320 ◽  
pp. 45-51
Author(s):  
Shun Yao Jin ◽  
Zhong Guo Huang ◽  
Zong Ke Shao ◽  
Qing Hua Yuan ◽  
Jian Wei
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Wall Thickness ◽  
Large Diameter ◽  
3D Models ◽  
Steel Tube ◽  
Element Analysis ◽  
Thickness Uniformity ◽  
Gas Cylinder ◽  
Hot Rolled

This paper expounds the application of rotary expanding process to manufacture the large-diameter hot-rolled seamless gas cylinder. 3D drawing software CATIA-V5 is applied to build 3d models of steel tube and rolling tools. Deformation feature of rotary expanding process is analyzed by using MSC.Marc FEA (finite element analysis) software to simulate the rolling process. As a result, it provides a scientific theory for optimizing the rotary expanding process and improving the quality of steel tube. It proposes a novel method to calculate the wall thickness uniformity after finite element analysis. Marc’s second development function and FORTRAN software’s extracting finite element node coordinates function are applied to calculate the wall thickness uniformity. The rotary expanding process can control the wall thickness uniformity well. The wall thickness uniformity of steel tube after rolling is simulated well by using MSC.Marc FEA software, which can help the technologist to predict the influence of wall thickness uniformity owing to the change of process design, and to provide guidance for production.

An Analysis of Stainless Steel Micro Square Hole-Flange Using Stretching Processes

2014 ◽  
Vol 626 ◽  
pp. 402-407
Author(s):  
Tsung Chia Chen ◽  
Ching Min Hsu
Keyword(s):  
Finite Element ◽  
Stainless Steel ◽  
Program Analysis ◽  
Thickness Distribution ◽  
Maximum Diameter ◽  
Flow Rule ◽  
Maximum Height ◽  
Forming Process ◽  
Element Analysis ◽  
Square Hole

This study is focused on the influences of micro stretching process, miniaturized of micro square hole-flange to stainless steel (SUS304) material, and different thicknesses (0.2, 0.1, 0.05mm) of plate. By undergoing finite element program analysis of material parameter corrected by scale factor, we can discover the differences of different thicknesses of plate during micro stretching forming process. The finite element method in this paper is combined with the plastic flow rule of Dynaform and LS-DYNA solver, finite element deformed theory, and updated Lagrangian formulation to simulate the process of micro square hole-flange. The point of this research is by simulating and analyzing all datum of micro stretching forming process, relation between punch load and stroke, distribution of thickness, distribution of stress and strain, the maximum diameter of flange’s hole and the maximum height of flange. Design three pairs of micro square hole-flange tool undergoing micro stretching experience through SUS304 plate. Compare the experience to the results of the simulation to test the reliability of this analyzing program. Through finite element analysis and the results of the experience, we can discover that the minimum of the thickness, the biggest stress and major strain centralize areas where blank and punch corner meet.

Development of Finite Element Analysis Model for Plug Mill Rolling

2014 ◽  
Vol 622-623 ◽  
pp. 899-904 ◽  
Author(s):  
T. Katsumura ◽  
Kazutoshi Ishikawa ◽  
Atsushi Matsumoto ◽  
Shunsuke Sasaki ◽  
Yasushi Kato ◽  
...  
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Wall Thickness ◽  
Thickness Distribution ◽  
Element Model ◽  
Rolling Process ◽  
Target Thickness ◽  
Analysis Model ◽  
Element Analysis ◽  
Finite Element Analysis Model

In the seamless pipe rolling process, the pipe wall thickness is largely determined at the mandrel mill or plug mill. It is possible to obtain the target thickness at these mills by defining the gap of a grooved roll and an inside tool such as a plug. However, the thickness of the free deformation part, which is not in contact with the roll and tool, had generally been estimated by experimental techniques. Although a number of analytical studies of mandrel mill rolling had been reported, few reports had examined plug mill rolling. Therefore, in this research, a finite element analysis model for plug mill rolling was developed by extending the rigid plasticity finite element model "Computational Rolling Mill (CORMILL)." Good agreement between the calculated results and experimental results was obtained for the wall thickness, and it was found that the thickness of the flange part decreases with reduction of the wall thickness at the grooved bottom. These results suggested that the wall thickness distribution of rolled pipes can be controlled by using a suitable inside tool and roll shape in each rolling pass, and the necessary shapes can be obtained by using the newly-developed model.

Finite-Element Analysis of Preform Deformation for Flat Wall Thickness Distribution in the Injection Blow Molding Process

2020 ◽  
Vol 987 ◽  
pp. 142-148
Author(s):  
Nuchnalin Atigkaphan ◽  
Satjarthip Thusneyapan
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Wall Thickness ◽  
Thickness Distribution ◽  
Molding Process ◽  
Element Analysis ◽  
Flat Wall ◽  
Blow Molding ◽  
Simulation Efficiency ◽  
Major Consideration

The wall thickness of plastic bottle is a major consideration for engineers in designing products with strength. For injection blow molding, the thickness depends on the preform size, and shape of the required product. The polyethylene terephthalate (PET) is injected in a mold with the shape of the preform. A stretch injection blow molding machine is used for processing the preform to the shape of the bottle. This research applied finite-element analysis for the process simulation; started from applying the air pressure inside the heated perform – until the PET expanded to the required bottle shape. While most studies were interested in axis-symmetry shape, this paper concentrated on a bottle with uniform flat wall thickness on four sides of a squared section bottle. Several finite-element models were studied and compared the simulation efficiency. Under the investigated area of ±15 mm x 90 mm, the thickness deviation found to be within 3.573%.

Finite Element Analysis of Hemispherical-Shape Parts in the Hot Gas Bulge-Forming of Polycarbonate (PC) Sheet

2007 ◽  
Vol 10-12 ◽  
pp. 140-144
Author(s):  
Zhen Xiu Hou ◽  
En Ren Liu ◽  
An Feng ◽  
Zhong Ren Wang
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Wall Thickness ◽  
Strain Distribution ◽  
Thickness Distribution ◽  
Experimental Result ◽  
Geometrical Shape ◽  
Element Analysis ◽  
Hot Gas ◽  
Critical Circle

To explore geometrical shape deforms, stress distribution, strain distribution and wall thickness of products in the process of polycarbonate (PC) hot gas pressure bulging, numerical simulation of 1mm thick hemispherical PC part with a diameter of 100mm has been conducted by the software of DYNAFORM. The result shows that abrupt changes tend to occur in the deforming of PC sheet as the even loaded pressure increases to a given point. A critical circle exists in the photoelastic experiment of latitude strain distribution, wall thickness distribution and displacement change, thus making the wall thickness of hemispherical part become gradually thick from critical circle part to pressure-pad-circle part. Importantly the experimental result fits well with the finite element analysis.

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