Quality of the Hydroformed Tubular Parts

Ceclan, Vasile Adrian; Balc, Nicolae; Grozav, Sorin; Bere, Paul; Borzan, Cristina Stefana

doi:10.4028/www.scientific.net/AEF.8-9.215

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Home Advanced Engineering Forum Interdisciplinary Research in Engineering: Steps...Quality of the Hydroformed Tubular Parts

Quality of the Hydroformed Tubular Parts

Abstract:

In this paper the authors shows hydroforming of tubular parts. Also it presents the technology of the hydroforming of the tubular parts. It is presented some experimental research compared with the prediction of the numerical simulation of this process. There are presented also the mechanical parameters of the material which are used in the field of the deforming process.

Info:

Periodical:

Advanced Engineering Forum (Volumes 8-9)

Main Theme:

Interdisciplinary Research in Engineering: Steps towards Breakthrough Innovation for Sustainable Development

Edited by:

Aurel Vlaicu and Stelian Brad

Pages:

215-224

DOI:

https://doi.org/10.4028/www.scientific.net/AEF.8-9.215

Citation:

V. A. Ceclan et al., "Quality of the Hydroformed Tubular Parts", Advanced Engineering Forum, Vols. 8-9, pp. 215-224, 2013

Online since:

June 2013

Authors:

Vasile Adrian Ceclan, Nicolae Balc, Sorin Grozav, Paul Bere, Cristina Stefana Borzan

Keywords:

Hydroforming, Numerical Simulation, Quality, Tubular Parts

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References

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[2] Zhubin He, Shijian Yuan, Gang Liu, Jia Wu, Weiwei Chat., Formability testing of AZ31B magnesium alloy tube at elevated temperature, Journal of Materials Processing Technology, 210 (2010) 877–884.

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[3] F. Vollertsen, State of the art and perspectives of hydroforming of tubes and sheets, J. Mater. Process. Technol. 17 (3) (2001) 321–324.

[4] F. Dohmann, Introduction of the processes of hydroforming, in Proceedings of the International Conference on Hydroforming, Stuttgart, October 1999, p.1–23.

[6] Schuler Gmbh (ed. ) Metal Forming Handbook. Berlin: Springer, (1998).

[7] Rebelo N, Nagtegall JC, Taylor LM. Industrial application of implicit and explicit finite element methods to forming processes. Numer Methods Simul Ind Metal Form Process ASME 1992: 67–76.

[8] A. Alaswad *, A.G. Olabi, K.Y. Benyounis, Integration of finite element analysis and design of experiments to analyse the geometrical factors in bi-layered tube hydroforming, Materials and Design10 July (2010).

DOI: https://doi.org/10.1016/j.matdes.2010.07.015

[9] Mehdi Imaninejad, Ghatu Subhash, Adam Loukus, Influence of end-conditions during tube hydroforming of aluminum extrusions, International Journal of Mechanical Sciences 46 (2004) 1195–1212.

DOI: https://doi.org/10.1016/j.ijmecsci.2004.08.001

[10] Asnafi N, Skogsga˚ rdh A. Theoretical and experimental analysis of stroke-controlled tube hydroforming. Journal of Materials Science & Engineering A (Switzerland) 2000; 279 (1–2): 95–110.

DOI: https://doi.org/10.1016/s0921-5093(99)00646-2

[11] Xia ZC. Failure analysis of tubular hydroforming. Journal of Engineering Materials and Technology 2001; 123: 423–9.

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DOI: https://doi.org/10.1016/s0020-7403(02)00031-0

[13] Xing HL, Makinouchi A. Numerical analysis and design for tubular hydroforming. International Journal of Mechanical Sciences 2001; 43: 1009–26.

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[16] Morovič, L. - Pokorný, P.: Optical 3D Scanning of Small Parts. Advanced Materials Research Vols. 468-471 (2012) pp.2269-2273, Trans Tech Publications, Switzerland, doi: 10. 4028.

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Paper TitlePages

Study on Product Design and Process Simulation of Hydroformed Automobile Framework

Authors: Lin Zhou, Xiao Min Cheng

Abstract: To achieve smaller weight, stronger strength and higher stiffness, tube hydroforming is widely used in the industry. The front beam is analysed the front beam part is redesigned based on the technics, and automotive structural lightweight and integration are achieved under the precondition of ensuring vehicle performance and security. Then, the hydroforming process of front beam is analyzed by numerical simulation based upon the elastic-plastic finite element method, Belytschko-Tsay shell element theory and dynamic explicit solution, the internal pressure loading path as the main hydroforming process parameters is discussed in detail. The present analysis provide basis for its applications.

210

Analysis and Finite Element Method Simulation of Rear Sub-Frame Hydroforming Process

Authors: Zhou De Qu

Abstract: The recent application of tube hydroforming in the automotive industry demands finite element analysis, since it is rapidly being used as an effective tool for the evaluation of the design of hydroforming processes. In this paper the formability of rear sub-frame in car body with tube hydroforming is studied. The comparison of various feeding and pressure on the hydroforming process is evaluated utilizing Finite Element Method to obtain detailed information on the deformation behaviors in hydroforming of rear sub-frame. It has been shown that optical leading paths such as axial feeding and internal pressure can quantify the circumferential thickness distribution in the rear sub-frame tube periphery.

191

An Investigation into Hydroforming of an X-Shape Pipe Connection

Authors: G.H. Majzoobi, H.R. Farhoudi, A. Shirazi

Abstract: In this work, hydroforming of X-shape pipe connection made of copper is investigated by experiment and numerical simulation. The length of the connection branch is always a concern. The main purpose of the work is the study of the effect of the branch end boundary condition and the load path on the branch height. An elastic material (called the constraint), such as a spring, is used for controlling the branch to grow to a certain extent. It is shown that the branch end condition, if designed properly, gives rise to the considerable increase in the branch length. The increase, however, depends also on the load path which must be determined by experiment or numerical simulation.

Flow Stress Determination of Steel Tube for Hydroformability Evaluation

Authors: P. Boonpuek, S. Jirathearanat, N. Depaiwa

Abstract: This study aims to determine flow stress of a steel tube by using hydraulic bulge test. A new proposed analytical model for analyzing bulge shapes of hydroformed tubes is postulated. Bulge test apparatus designed using FEA simulation of hydroforming and STKM 11A steel tubes are used in the hydraulic bulge test. Bulge heights and internal pressures are measured during bulge testing. Tube thicknesses at vertex of a bulge shape are measured by a dial caliper gauge. Bulge curvatures and contact points are measured by taking digital photos of bulge shapes combined with measurement methods in CAD software. Effective stress - strain relationships are obtained from the newly developed analytical model using those measured values. Flow stress curves obtained from the effective stress – strain relationships are compared with those by other researchers and tensile test. Finite element analysis methods are used to conduct simulation of tube hydroforming using the flow stress curves. Predicted internal pressures versus bulge heights and tube thicknesses are compared with experimental results. Verification of the developed analytical model is presented. The flow stress at neck point of formed tube is determined.

656

Application of Tube Hydroforming in Square Cross-Section Die for Inverse Identification Method Validation

Authors: Ali Khalfallah, Temim Zribi, Hedi Belhadj Salah

Abstract: Tube hydroforming processes are an excellent way for manufacturing reduced weight parts with complex shapes in widespread fields. Accurate numerical simulation of tube hydroforming process is particularly based on precise material parameters deduced from experimental tests. The free bulge test is widely employed for the parameter identification of tubular material behavior models by means of analytical [1] and numerical methods [2]. In this context, an inverse identification methodology using free bulge tests was developed. These tests were carried out by means of a new home-designed and manufactured bulge forming machine. The objective of this work is the validation of the inverse identification method using tube hydroforming in square cross-section die. The analysis of this particular hydroforming process with respect to material parameters is performed. For this purpose, circular section tubes made of low carbon steel S235 and aluminum alloy AA6063-O are hydroformed against square-cross sectional die using our bulge forming machine. Afterwards, FE model is constructed to simulate square-sectional hydroformed parts. The influence of some parameters, such as strain hardening exponent, anisotropy parameter and friction coefficient, on numerical square cross-sectional hydroformed part thickness is analyzed. It permits to assess the sensitivity of the thickness relative to used material parameters in the FE model. In order to validate the inverse identification procedure for both materials, experimental thicknesses along the profile of cross-sectional hydroformed parts are measured and compared with the corresponding numerical thicknesses predicted by FE model. It is proven after analyzing the obtained results that the chosen response, i.e. thickness distribution along the profile of the tube hydroforming against the square cross-section die, used for the validation is sensitive to the identified material properties. Particularly, it is demonstrated for low carbon steel S235 that numerical thickness is in good agreement with experimental data. However, for aluminum alloy AA6063-O, a discrepancy between experimental and predicted thicknesses is noticed. Anyway, it is demonstrated that inverse identification approach leads to sufficiently accurate parameters used for numerical tube hydroforming simulations. Furthermore, it seems that Hill48’s yield criterion is more suitable for describing steels plastic behavior than aluminum alloys for tube hydroforming processes. Concerning aluminum alloy, certainly the choice of appropriate yield criterion is of paramount importance on the prediction of tubular plastic behavior in tube hydroforming. Consequently, it is shown that the use of simple tube hydroforming in square-section die is suitable for the validation of FE model which is identified by inverse method using free bulge test.

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