Analysis of the Hydroforming Process Using Metamodels

Abstract:

In this paper, an original method is presented for evaluating the probability of failure in a precise manner in the tube hydroforming process (THP). This process consists to apply an inner pressure combined to an axial displacement to manufacture the part. During the manufacturing phase, inappropriate choice of the load paths can lead to failure. Our approach is to determine the space failure probability for each item in the area is critical. It is defined by identifying the critical element, and then a patch is defined on this item that represents the area of the most probable failure. The identification of the critical element for each failure mode is done by reference the state of strain on the forming limit curve (FLC) of the material. Access to the probability of space failure allows to give an idea on the stability of the process and also to predict the most likely area where plastic instability can appear. The failure probability estimation based on a characterization probabilistic principal strains (major and minor) for each failure mode and for each element. Access to this probability of failure in a direct manner is impossible given the complexity of the treated problem and the huge number of calculations by finite elements necessary. To compensate for this problem, approximation techniques have been used to replace the real model by metamodel that enables to evaluate the response quickly and allows us to get an idea on the stability of the process.Keywords: Hydroforming process, metamodels, random, forming limit curve (FLC), failure mode, finite element.

• Periodical: Advanced Materials Research (Volume 1099)
• Pages: 52-60
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.1099.52
• Online since: April 2015
• Authors: Abdelkhalak El Hami, Bouchaib Radi*
• Keywords: Failure Mode, Finite Element, Forming Limit Curve (FLC), Hydroforming Process, Metamodels, Random

References

[1] Der Kiureghian A, Jyh-Bin K. The stochastic finite element method in structural Reliability. Probabilistic Engineering Mechanics 1988; 3(2): 83-91.

DOI: 10.1016/0266-8920(88)90019-7

[2] Sudret B, Der Kiureghian A. Comparison of finite element reliability methods. Probabilistic Engineering Mechanics 2002; 17: 337–348.

DOI: 10.1016/s0266-8920(02)00031-0

[3] Cacciola P, Maugeri N, Muscolino G. A modal correction method for non-stationary random vibrations of linear systems. Probabilistic Engineering Mechanics 2007; 22: 170–180.

DOI: 10.1016/j.probengmech.2006.10.002

[4] Moro T, El Hami A, El Moudni A. Reliability Analysis of a mechanical contact between deformable solids. Probabilist. Eng. Mech. 2002; 17(3): 227–232.

DOI: 10.1016/s0266-8920(02)00007-3

[5] Kleiber M, Rojek J, Stocki R. Reliability assessment for sheet metal forming operations. Computer Methods in Applied Mechanics and Engineering 2002; 191: 4511–4532.

DOI: 10.1016/s0045-7825(02)00394-8

[6] Bing L, Nye TJ, Metzger Don R. Improving the reliability of the tube-hydroforming process by the Taguchi Method. J Pressure Vessel Technology 2007; 129: 242-247.

DOI: 10.1115/1.2716427

[7] Radi, B and El Hami, A. Reliability analysis of the metal forming process. Mathematical and Computer Modelling 2007; 45: 431–439.

DOI: 10.1016/j.mcm.2006.05.013

[8] Aydemir, A et al. An adaptive simulation approach designed for tube hydroforming processes. J Materials Processing Technology 2004; 159: 303-310.

DOI: 10.1016/j.jmatprotec.2004.05.018

[9] Jansson, M, et al. On process parameter estimation for the tube hydroforming process. J Materials Processing Technology 2007; 190: 1-11.

DOI: 10.1016/j.jmatprotec.2007.02.050

[10] Fann, K-J. and P-Y. Hsiao. Optimization of loading conditions for tube hydroforming. J Materials Processing Technology 2003; 140: 520-524.

DOI: 10.1016/s0924-0136(03)00778-7

[11] Imaninejad, M. et al. Loading path optimization of tube hydroforming process. I J Machine Tools & Manufacture 2005; 45: 1504-1515.

DOI: 10.1016/j.ijmachtools.2005.01.029

[12] Abedrabbo, N. et al. Wrinkling control in aluminum sheet hydroforming. I J Mechanical Sciences 2005; 47: 333–358.

DOI: 10.1016/j.ijmecsci.2005.02.003

[13] Mohsine A. and El Hami A. A Robust Study of Reliability-Based Optimisation Methods under Eigen-frequency. International Journal of Computer Methods in Applied Mechanics and Engineering 2010; 199(17-20): 1006-1018.

DOI: 10.1016/j.cma.2009.11.012

[14] El Hami A., Radi B. and Cherouat A. The frictional contact of the shaping of the composite fabric. International Journal of Mathematical and Computer Modelling 2009; 49: 1337-1349.

DOI: 10.1016/j.mcm.2008.09.016

[15] Cherouat A. Radi B. and El Hami A. The frictional contact of the shaping of the composite fabric. I J Acta Mecanica 2009, 199(1-4): 29-41.

DOI: 10.1007/s00707-007-0566-1

[16] Radi B. and El Hami A. Reliability analysis of the metal forming process. International Journal of Mathematical and Computer Modelling 2007; 45: 431-439.

DOI: 10.1016/j.mcm.2006.05.013

[17] Karthik V. et al. Variability of sheet formability and formability testing. J of Mat Proc Technology 2002; 121: 350–362.

DOI: 10.1016/s0924-0136(01)01219-5

[18] Gantar G, Kuzman K. Optimization of stamping processes aiming at maximal process stability. J of Mat Proc Technology 2005; 167: 237-243.

DOI: 10.1016/j.jmatprotec.2005.05.027

[19] Cao J, Krishnan N. Estimation of optimal blank holder force trajectories in segmented binders using ARMA model. J of Manuf Science and Engineering 2003; 125: 763-770.

DOI: 10.1115/1.1616948

[20] Majeske KD, Hammett PC. Identifying sources of variation in sheet metal stamping. I J of Flex Manufacturing Systems 2003; 15: 5–18.

[19] ABAQUS/Explicit Users Manual. ABAQUS Inc. Version 6. 5, (2005).

[20] M. Ben-Taher. Contributions à l'étude et la simulation du procédé d'hydroformage. PhD thesis, Ecole des Mines de Paris (2005).

[21] Sarsri D., Azrar L. and Jebbouri A. and El Hami A. Component mode synthesis and polynomial chaos expansions for stochastic frequency functions of large linear FE models. Computers & Structures 2011; 89: 346-356.

DOI: 10.1016/j.compstruc.2010.11.009