Tube and Sheet Hydroforming-Advances in Material Modeling, Tooling and Process Simulation

Abstract:

Article Preview

Tube Hydroforming is a well accepted production technology in automotive industry while sheet hydroforming is used in selected cases for prototyping and low volume production. Research in advanced methods (warm sheet and tube hydroforming, double blank sheet hydroforming, combination of hydroforming and mechanical sizing, use of multi-point and elastic blank holders) is expanding the capabilities of hydroforming technologies to produce parts from Al and Mg alloys, as well as Ultra High Strength Steels. In the development of advanced hydroforming methods, experience based knowledge is not readily available. Thus, robust process simulation is required, along with adequate material modeling and identification of friction coefficients as input to process simulation. This paper gives an overview of advanced hydroforming methods, including examples of novel machine and tooling designs. The use of reliable process simulation is illustrated with examples that demonstrate the significance of material and friction date for making accurate predictions. Advanced simulation methods for warm forming and for programming multiple-point blank holder are also discussed. This review illustrates that hydroforming continues to make advances and has the potential to make many contributions to production technology in the near future.

Info:

Periodical:

Main Theme:

Edited by:

M. Geiger, J. Duflou, H.J.J. Kals, B. Shirvani and U.P. Singh

Pages:

1-12

Citation:

T. Altan et al., "Tube and Sheet Hydroforming-Advances in Material Modeling, Tooling and Process Simulation", Advanced Materials Research, Vols. 6-8, pp. 1-12, 2005

Online since:

May 2005

Export:

Price:

$38.00

[1] Schmoeckel, D., Hielscher, C., Huber R., 1999, Metal forming of tubes and sheets with liquid and other flexible media, Annals of CIRP, Vol 48/2/, pp.1-20.

DOI: https://doi.org/10.1016/s0007-8506(07)63230-2

[2] Ahmetoglu, M., Altan, T., 2000, Tube Hydroforming: State of the art and future trends, Journal of Material Processing Technology, Vol 98, pp.25-33.

DOI: https://doi.org/10.1016/s0924-0136(99)00302-7

[3] Ngaile, G., Jager, S., Altan, T., 2004, Lubrication in tube hydroforming (THF) Part I. Lubrication mechanisms and development of model tests to evaluate lubricants and die coatings in the transition and expansion zones, Journal of Material Processing Technology, Vol 146, pp.108-115.

DOI: https://doi.org/10.1016/s0924-0136(03)00850-1

[3] Siegert, K., Oberpriller, B., Markstadter, H., 2003, Hydromechanical deep drawing of car outer panels, Hydroforming of Tubes , Extrusions and Sheet Metals, Edited by K Siegert, Vol 3, pp.551-567.

[4] Marando, R.A., Kapp, D., 2003, Hydro forming C-frame press with a closing force of 130, 000kN, Hydroforming of Tubes , Extrusions and Sheet Metals, Edited by K Siegert, Vol 3, pp.389-409.

[5] Macrae, C., Heinmann,W., 2003, Machines used for producing hydroformed components the past, the present , the future, Hydroforming of Tubes , Extrusions and Sheet Metals, Edited by K Siegert, Vol 3, pp.473-480.

[6] Breckner, M., 1999, Hydraulic system for hydroforming, Hydroforming of Tubes , Extrusions and Sheet Metals, Edited by K Siegert, Vol 1, pp.173-190.

[7] Jirathearanat, S., Altan, T., 2004, Advanced methods for finite element simulation for process design in tube hydroforming, ERC Report No: THF/ERC/NSM-04-R-31, The Ohio State University, Columbus, Ohio.

[8] Kleiner, M., Homberg, W., 2001, New 100, 000 kN press for sheet hydroforming, Hydroforming of Tubes and Extrusions and Sheet Metals, Edited by K. Siegert, Vol 2, pp.351-362.

[9] Geiger , M., Tolazzi, M., 2004, Process optimization in sheet hydrforming, Submitted to Journal of Material Processing Technology.

[10] Aust, M., 2001, Modified hydromechanical deep-drawing, Hydroforming of Tubes, Extrusions and Sheet Metals, Edited by K Siegert, Vol 2, pp.215-234.

[11] Maki, T., 2003, Current status of fluid forming in the automotive industry, Hydroforming of Tubes, Extrusions and Sheet Metals, Edited by K Siegert, Vol 3, pp.25-44.

[12] Schnupp, K., Kerschner, M., 2003, Presses for hydromechanical drawing of panels for automobiles, Hydroforming of Tubes, Extrusions and Sheet Metals, Edited by K Siegert, Vol 3, pp.409-421.

[13] Stremme, D., Cherek, H., Kolleck, R., Manufacturing of large size outer panels using active hydromechanical sheet metal forming, Hydroforming of Tubes, Extrusions and Sheet Metals, Edited by K Siegert, Vol 2, pp.249-258.

[14] Habil, Neugebauer, R., Schnapel, J., Muth, E., Braunlich, H., 2003, Hydroforming sheetmetals as a tooling scheme for series production, Hydroforming of Tubes , Extrusions and Sheet Metals, Edited by K Siegert, Vol 3, pp.371-388.

[15] Schwarz, S., Lenze, F., J., Aust, M., Schneider, S., 2003, Sheet metal hydroforming for auto body applications, Hydroforming of Tubes , Extrusions and Sheet Metals, Edited by K Siegert, Vol 3, pp.199-216.

[16] Pasino, R., Prier, M., 2003, Progress in hydroforming double sheets, Hydroforming of Tubes , Extrusions and Sheet Metals, Edited by K Siegert, Vol 3, pp.217-226.

[17] Schroder, M., 2003, Recent developments in the hydroforming of tubular and sheet blanks - semi productive and productive, Hydroforming of Tubes , Extrusions and Sheet Metals, Edited by K Siegert, Vol 3, pp.165-183.

[18] Kleiner, M., Kopp, R., Homberg, W., Krahn, M., Krux, R., Putten, K.V., 2004, High-pressure sheet metal forming of tailor rolled blanks, submitted for publication.

DOI: https://doi.org/10.1002/srin.200506112

[19] Birkert, A., Neubert, J., Gruszka, T., 1999, Parallel plate hydroforming, Hydroforming of Tubes, Extrusions and Sheet Metals, Edited by K Siegert, Vol 2, pp.283-296.

[20] Novotny, S., Hein, P., 2001, Hydroforming of sheet metal pairs from aluminum alloys, Journal of Materials Processing Technology, Vol. 115, pp.65-69.

DOI: https://doi.org/10.1016/s0924-0136(01)00766-x

[21] Keri, M., 1999, State of the art of sealing techniques for hydroforming tools, Hydroforming of Tubes , Extrusions and Sheet Metals, Edited by K Siegert, Vol 3, pp.441-461.

[22] Geiger, M., Celeghini, M., Haldenwanger, G., Prier, M., 2003, Sheet and Tube Hydroforming at elevated temperatures, Hydroforming of Tubes, Extrusions and Sheet Metals, Edited by K Siegert, Vol 3, pp.259-278.

[23] Groche, R., Huber, R., Dorr, J., Schmoeckel, D., 2002, Hydromechanical deep drawing of aluminum alloys at elevated temperatures, Annals of CIRP, Vol 51/1/, pp.215-218.

DOI: https://doi.org/10.1016/s0007-8506(07)61502-9

[24] Jager, S., 2003, Forming of Magnesium sheet metal, Hydroforming of Tubes , Extrusions and Sheet Metals, Edited by K Siegert, Vol 3, pp.463-472.

[25] Neugebauer, R., Seifert, M., 2003, Results of tempered hydroforming of magnesium sheets with hydroforming fluids, Proceedings of the 6th International conference of magnesium Alloys and their applications, pp.306-312.

DOI: https://doi.org/10.1002/3527603565.ch47

[26] Behrens, B.A., Kurz, G., Hubner, S., 2004, Heated hydro-mechanical deep drawing of magnesium sheet metal , New Developments in Sheet Metal Forming, Edited by K. Siegert, pp.379-398.

DOI: https://doi.org/10.1007/978-3-319-48099-2_62