A modified MK model combined with ductile fracture criterion（DFC-MK model） is proposed to compute the forming limit diagrams（FLDs） of 5A06-O aluminum alloy sheet at different temperatures.The material constant（C...A modified MK model combined with ductile fracture criterion（DFC-MK model） is proposed to compute the forming limit diagrams（FLDs） of 5A06-O aluminum alloy sheet at different temperatures.The material constant（C） of ductile fracture criterion and initial thickness imperfection parameter（f0） at various temperatures are determined by using a new computing method based on wide sheet bending test.The FLDs at 20 and 200 °C are calculated through the DFC-MK model.The DFC-MK model,which includes the influence of through-thickness normal stress,is written into the subroutine VUMAT embedded in Abaqus/ Explicit.The cylindrical cup hydroforming tests are carried out to verify the model.The results show that compared with experimental observations,the predicted FLDs based on DFC-MK model are more accurate than the conventional MK model;the errors between the simulations and experiments in warm hydroforming are 8.23% at 20 °C and 9.24% at 200 °C,which verify the effectiveness of the proposed model.展开更多
Because of the complex constraint effects among layers in multi-layered metallic bellows hydroforming,the stress concentration and defects such as wrinkling and fracture may easily occur.It is a key to reveal the defo...Because of the complex constraint effects among layers in multi-layered metallic bellows hydroforming,the stress concentration and defects such as wrinkling and fracture may easily occur.It is a key to reveal the deformation behaviors in order to obtain a sound product.Based on the ABAQUS platform,a 3 D-FE model of the four-layered U-shaped metallic bellow hydroforming process is established and validated by experiment.The stress and strain distributions,wall thickness variations and bellow profiles of each layer in the whole process,including bulging,folding and springback stages,are studied.Then deformation behaviors of bellows under different forming conditions are discussed.It is found that the wall thinning degrees of different layer vary after hydroforming,and is the largest for the inner layer and smallest for the outer layer.At folding stage,the wall thinning degree of the crown point increases lineally,and the difference among layers increases as the process going.The displacements of the crown point decrease from the inner layer to the outer layer.After springback,the U-shaped cross section changes to a tongue shape,the change of convolution pitch is much larger than the change of convolution height,and the springback values of the inner layer are smaller than the outer layer.An increase in the internal pressure and die spacing cause the maximum wall thinning degree and springback increase.With changing of process parameters,bellows with deep convolution are easily encountered wall thinning during hydroforming and convolution distortion after springback.This research is helpful for precision forming of multi-layered bellows.展开更多
In order to reduce high calibration pressure in hydroforming of components with too small radii, a method wasproposed to manufacture automotive hollow components with rectangular shape by relatively lower pressure. Th...In order to reduce high calibration pressure in hydroforming of components with too small radii, a method wasproposed to manufacture automotive hollow components with rectangular shape by relatively lower pressure. Theprocess is simulated and analyzed. It is thought that the friction force between the die surface and tube is a mainreason that high pressure is needed to form small radii. Using the method proposed in this paper, a petal-like sectionshape is first preformed so that the central zones of the four sides of the preform section do not contact with the diesides, thus the tube metal is easy to flow into the transition radii area in calibration stage. Moreover, a positive forcealong the sides is produced by the internal pressure, which is beneficial to overcome the friction force and push thematerial into the radii. Therefore, the pressure for forming the transition radii is greatly reduced and the componentswith small radii can be formed with relatively lower pressure. For the experimental case conducted in this paper, theforming pressure is reduced by about 28.6% than the estimated forming pressure.展开更多
The friction coefficient between tube and die in guide zone of tube hydroforming was obtained. In hydroforming, the tube is expanded by an internal pressure against the tool wall. By pushing the tube through tool, a f...The friction coefficient between tube and die in guide zone of tube hydroforming was obtained. In hydroforming, the tube is expanded by an internal pressure against the tool wall. By pushing the tube through tool, a friction force at the contact surface between the tube and the tool occurs. In guiding zone, the friction coefficients between tube and die can be estimated from the measured axial feeding forces. In expansion zone, the friction coefficients between tube and die can be evaluated from the measured geometries of expanded tubes and FE analysis.展开更多
The uniaxial tensile test of the 5A06-O aluminium−magnesium(Al−Mg)alloy sheet was performed in the temperature range of 20−300℃ to obtain the true stress−true strain curves at different temperatures and strain rates....The uniaxial tensile test of the 5A06-O aluminium−magnesium(Al−Mg)alloy sheet was performed in the temperature range of 20−300℃ to obtain the true stress−true strain curves at different temperatures and strain rates.The constitutive model of 5A06-O Al−Mg alloy sheet with the temperature range from 150 to 300℃ was established.Based on the test results,a unique finite element simulation platform for warm hydroforming of 5A06-O Al−Mg alloy was set up using the general finite element software MSC.Marc to simulate warm hydroforming of classic specimen,and a coupled thermo-mechanical finite element model for warm hydroforming of cylindrical cup was built up.Combined with the experiment,the influence of the temperature field distribution and loading conditions on the sheet formability was studied.The results show that the non-isothermal temperature distribution conditions can significantly improve the forming performance of the material.As the temperature increases,the impact of the punching speed on the forming becomes particularly obvious;the optimal values of the fluid pressure and blank holder force required for forming are reduced.展开更多
The study of multipoint blank holder force（BHF） control is carried out for hydroforming a complicated shape motorcycle fuel tank. By finite element method （FEM） simulation, the configuration of multipoint blank ho...The study of multipoint blank holder force（BHF） control is carried out for hydroforming a complicated shape motorcycle fuel tank. By finite element method （FEM） simulation, the configuration of multipoint blank holder cylinders and the setting of local BHF are optimized, and the influences of the multipoint BHF on the hydromechanical deep drawing and conventional hydroforming processes are studied. The desired fluid pressure and whole BHF are predicted for hydromechanical deep drawing process. Finally, simulation results are testified by forming experiment, and they are in agreement very well.展开更多
A new process of hydroforming with controllable radial pressure was proposed to overcome difficulties in the forming of low plastic materials and large height-to-diameter ratio workpieces. A typical 5A06 aluminum allo...A new process of hydroforming with controllable radial pressure was proposed to overcome difficulties in the forming of low plastic materials and large height-to-diameter ratio workpieces. A typical 5A06 aluminum alloy dome was numerically and experimentally investigated. The reasons for typical defects were analyzed under different radial pressures. Effects of radial pressure on the thickness distribution were discussed and optimal radial pressure was determined. It is shown by numerical simulations and experiment that a cup with a drawing ratio of 2.4 is formed by the new process of hydroforming with controllable radial pressure. It is significantly effective for the forming of low plastic materials and large height-to-diameter ratio workpieees. Two typical thinning points exit along the dome wall. With the radial pressure, thinning is decreased effectively at the two points, the dome forming is achieved and thickness distribution is more uniform.展开更多
In tube hydroforming with axial feeding,under the effect of coupled internal pressure and axial stress,wrinkles often occur and affect the forming results.Wrinkling behavior of an AZ31B magnesium alloy tube was experi...In tube hydroforming with axial feeding,under the effect of coupled internal pressure and axial stress,wrinkles often occur and affect the forming results.Wrinkling behavior of an AZ31B magnesium alloy tube was experimentally investigated with different loading paths at different temperatures.Features of wrinkles,including shape,radius and width,were acquired from the experiments,as well as the thickness distribution.Numerical simulations were carried out to reveal the stress state during warm hydroforming,and then the strain history of material at the top and bottom of the wrinkles were analyzed according to the stress tracks and yielding ellipse.Finally,effects of loading paths on expansion ratio limit of warm hydroforming were analyzed.It is verified that at a certain temperature,expansion ratio limit can be increased obviously by applying a proper loading path and realizing enough axial feeding.展开更多
The hydroforming experiment of aluminum tubular part with rectangular section was carried out to investigate influence of axial feeding on thickness distribution and calibration pressure of the corner.Thickness distri...The hydroforming experiment of aluminum tubular part with rectangular section was carried out to investigate influence of axial feeding on thickness distribution and calibration pressure of the corner.Thickness distribution and relation between corner radius and internal pressure were analyzed.The influence of lubricant was discussed.Microstructure and hardness of different region were observed.It is shown that thickness reduction in the transition region between the corner and center region is the biggest.Friction condition has influence both on the thickness distribution and calibration pressure of the corner.As the increase of the axial feeding,the calibration pressure is decreased.There is only little change for the microstructure,but the hardness is increased by 23.3% for the transition region.展开更多
Tube hydroforming process is a relative new process f or production of structural parts of low weight and high rigidity. The successfu lness of the process depends largely on the a proper selection of loading path w h...Tube hydroforming process is a relative new process f or production of structural parts of low weight and high rigidity. The successfu lness of the process depends largely on the a proper selection of loading path w hich is axial feeding distance as related to the applied internal pressure. Due to the complicated nature of plastic deformation, a optimum loading path which w ill guarantee good hydroformed parts free of winkle and fracture has often to be determined by finite element analysis. In order to save trials and errors, adap tive FEM simulation method has been developed. To effectively apply the adaptive simulation method, we have to know the applicability of the method. In this pap er, a classification of tube hydroforming (THF) processes based on sensitivity to loading parameters has been suggested. Characteristics of the classification have been analyzed in terms of failure mode, dominant loading parameters and th eir working windows. It was discussed that the so called pressure dominant THF p rocess is the most difficult process for both simulation in FEM analysis and pra ctical operation in real manufacturing situation. To effectively find out the op timum loading path for pressure dominant THF process, adaptive FEM simulation st rategies are mostly needed.展开更多
Advanced high strength steels are the group of material with high strength and good formability, because high strength lesser gauge thickness can be used without compromising the function of component. In terms of eco...Advanced high strength steels are the group of material with high strength and good formability, because high strength lesser gauge thickness can be used without compromising the function of component. In terms of economic forming process, hydroforming is the manufacturing option which uses a fluid medium to form a component by using high internal pressure. This process gained steep interest in the automotive and aerospace industries because of its many advantages such as part consolidation, good quality of the formed part etc. The main advantage is that the uniform pressure can be transferred to whole projected part at the same time. Low pressure tube hydroforming considered an inexpensive option for forming these advanced high strength steel. This paper investigates the pressurization system used during the low pressure tube hydroforming cycle. It is observed that the usage of ramp pressure cycle during forming the part from low pressure tube hydroforming results in lesser die holding force. Also, the stress, strain and thickness distribution of the part during low pressure tube hydroforming are critically analysed.展开更多
The effects of temperature on the mechanical properties and elongation of AZ61A tubular part were derived by uni-axial tension tests at various temperatures.Warm hydroforming of an AZ61A tubular part for passenger car...The effects of temperature on the mechanical properties and elongation of AZ61A tubular part were derived by uni-axial tension tests at various temperatures.Warm hydroforming of an AZ61A tubular part for passenger car was then numerically and experimentally investigated.The complete processes including bending,pre-forming and hydroforming were analyzed and discussed. Microstructure at the corner of the typical section was observed before and after the final hydroforming process.It is shown that the yielding strength,tensile strength and total elongation increase as temperature increases,while the elongation before necking decreases.The temperature range from 225℃to 250 ℃is more suitable for hydroforming of theAZ61A magnesium alloy tube with various cross sections.Pre-forming and hydroforming with high strain values are feasible at elevated temperature.Grain refinement is observed at the corner of the part after warm hydroforming.Thinning ratio analysis illustrates that non-uniform deformation at elevated temperature should be considered in process optimization to avoid severe local thinning.展开更多
The internal pressure of the process was studied theoretically and experimentally. The external load character and internal stress character of tube hydroforming were discussed first. Then, according to the characters...The internal pressure of the process was studied theoretically and experimentally. The external load character and internal stress character of tube hydroforming were discussed first. Then, according to the characters, the function and classification of internal pressure were presented in general. Base on the stress analysis, its effect on the yield criterion and calculation formula were also researched and derived. To verify the correction of the theoretical analysis and derived formula, experiments with different internal pressures were carried out and the result was compared and discussed. It demonstrates that internal pressure plays an important role in tube hydroforming and theory and formula discussed and derived by this paper are feasible in practice.展开更多
To obtain the influence of fluid pressure and temperature on warm hydroforming of 5A06-O aluminum alloy sheet, the unified mechanics equilibrium equations, which take through- thickness normal stress and friction into...To obtain the influence of fluid pressure and temperature on warm hydroforming of 5A06-O aluminum alloy sheet, the unified mechanics equilibrium equations, which take through- thickness normal stress and friction into account, were established in spherical coordinate system. The distribution of through-thickness normal stress in the thickness direction was determined. The relation between through-thickness normal stress and fluid pressure was also analyzed in different regions of cylindrical cup. Based on the method of subtracting one increasing function from another, the constitutive equation of 5A06-O applied to warm hydroforming was established and in a good agreement with uniaxial tensile data. Based on whether the thickness variation was taken into account, two mechanic models were established to do the comparative study. The results for the studied case show that the calculated stress values are pretty close according to the two models and consistent with results of finite element analysis; the thickness distribution in flange computed by the second model conforms to the experimental data. Finally, the influences of fluid pressure on the flange thickness and radial stress were analyzed.展开更多
Perfect combination of structural size parameters of the hydroforming billets is essential to obtain even wall thicknesses of the car beam. Finite element （ FE ） analysis on hydroforming car beam was carried out, a...Perfect combination of structural size parameters of the hydroforming billets is essential to obtain even wall thicknesses of the car beam. Finite element （ FE ） analysis on hydroforming car beam was carried out, and the results were optimized according to multiple quality objectives by the grey system theory. With bending angle, bending radius and hight difference along the axis direction as variables, orthogonal FE analyses were conducted and the minimum and maximum wall thicknes ses of the billets with different sizes were obtained. Taking the minimum and maximum wall thick nesses as two references, the correlation coefficient between the data for reference and those for comparison by the grey system theory reduced multi objectives to a single quality objective, and the average correlation level of every billet facilitated the optimization of size parameters for hydroform ing car beam. The trial production showed that the optimization approach satisfied the need of hy droforming car beams.展开更多
An investigation was conducted on how to control loading path and its effect on thickness distribution after hydroforming crankshaft by using finite element simulation. Four different loading paths were utilized in si...An investigation was conducted on how to control loading path and its effect on thickness distribution after hydroforming crankshaft by using finite element simulation. Four different loading paths were utilized in simulating the forming process of hydroforming crankshaft and the results of different loading paths were presented. It shows that the hydroforming is dependent on the appropriate loading path. There exists the zone of hydroforming process window which can be confirmed by using simulation method. Wrinkles occur as the the internal pressure is less than 20MPa and bursting occurs as the the internal pressure is larger than 32MPa. Only when the internal pressure locates between 20MPa and 30MPa, can an eligible crankshaft component be manufactured.展开更多
A new hydroforming process for manufacturing corrosion-resistant-alloy(CRA)-lined pipe is proposed to overcome the disadvantages in existing technologies, and a new kindof hydraulic expansion device for bimetallic CRA...A new hydroforming process for manufacturing corrosion-resistant-alloy(CRA)-lined pipe is proposed to overcome the disadvantages in existing technologies, and a new kindof hydraulic expansion device for bimetallic CRA-lined pipe has been researched and developed. Itsoperational principal and technical characteristic is also introduced. The stress and strain in theliner and outer pipe during the hydroforming process have been analyzed and the mechanism ofhydraulic expansion method is studied theoretically. The final forming pressure formula is suggestedand the theoretical analysis is verified by experimental investigation. The results indicate thatthe new technology is feasible and can be applied in industrial production.展开更多
According to characteristic of hydroforming of parallel multi-branch tubes,multi-objective problems were transformed to single objective problem of relational grade comparison by grey system theory.Two different objec...According to characteristic of hydroforming of parallel multi-branch tubes,multi-objective problems were transformed to single objective problem of relational grade comparison by grey system theory.Two different objectives were selected,according to the principle that process parameters were optimal which of grey relational grade were maximum,the optimal loading parameters under different objective condition were obtained,and loading paths were optimized.The results indicated that parallel multi-branch tubes hydroformed under loading paths optimized by grey system theory could meet with the requirement that objective was optimal.And the optimal loading paths under different objectives were different,and the appropriate objective should be selected according to forming characteristic.展开更多
Process of warm tube hydroforming was experimentally investigated for forming an AZ31B magnesium alloy tubular part with a large expansion ratio. Effects of temperature on the mechanical properties and formability wer...Process of warm tube hydroforming was experimentally investigated for forming an AZ31B magnesium alloy tubular part with a large expansion ratio. Effects of temperature on the mechanical properties and formability were studied by uniaxial tensile test and hydraulic bulge test. Total elongation increases with temperature up to 250℃, but uniform elongation and maximum expansion ratio get the highest value at 175℃. Different axial feeding amounts were applied in experiments to determine the reasonable loading path. A preform with useful wrinkles was then realized and the tubular part with an expansion ratio of 50% was formed. Finally, mechanical condition to produce useful wrinkles is deduced and the result illustrates that useful wrinkles are easier to be obtained for tube with higher strain hardening coefficient value and tubular part with smaller expansion ratio.展开更多
Both experimental and mechanical analyses were carded out to investigate the characteristics of thickness distribution for tailor-welded tube （TWT） hydroforming with dissimilar thickness. Then, the effects of weld-s...Both experimental and mechanical analyses were carded out to investigate the characteristics of thickness distribution for tailor-welded tube （TWT） hydroforming with dissimilar thickness. Then, the effects of weld-seam position and thickness difference were also revealed. A multiple-diameter tube was formed to reveal the characteristics and the regularity of thickness distribution during TWT hydroforming. It is indicated that there are obvious fluctuations in thickness distribution though the TWTs have the same expansion ratio. The thinning ratio of thinner tube is bigger than that of thicker tube especially in the zone closed to the weld-seam. The difference in thinning ratio between two tube segments can reach 9%. Consequently, sudden and large fluctuation of thickness appears in the zone nearby the weld-seam. The difference in thinning ratio between thinner and thicker tubes enlarges as the thickness difference increases, but improves as length ratio increases. Different strain states are the main reason to induce nonuniform thickness distribution. The difference in thickness is the main reason to induce different strain states on thinner and thicker tubes.展开更多
基金Project(51175024)supported by the National Natural Science Foundation of China
文摘A modified MK model combined with ductile fracture criterion（DFC-MK model） is proposed to compute the forming limit diagrams（FLDs） of 5A06-O aluminum alloy sheet at different temperatures.The material constant（C） of ductile fracture criterion and initial thickness imperfection parameter（f0） at various temperatures are determined by using a new computing method based on wide sheet bending test.The FLDs at 20 and 200 °C are calculated through the DFC-MK model.The DFC-MK model,which includes the influence of through-thickness normal stress,is written into the subroutine VUMAT embedded in Abaqus/ Explicit.The cylindrical cup hydroforming tests are carried out to verify the model.The results show that compared with experimental observations,the predicted FLDs based on DFC-MK model are more accurate than the conventional MK model;the errors between the simulations and experiments in warm hydroforming are 8.23% at 20 °C and 9.24% at 200 °C,which verify the effectiveness of the proposed model.
基金the funds of the National Natural Science Foundation of China(No.51875456)the Natural Science Basic Research Plan in Shaanxi Province of China(No.2019JM-450)+3 种基金the Young Talent fund of University Association for Science and Technology in Shaanxi,China(No.20170518)the Key Laboratory of Advanced Manufacture Technology for Automobile Parts(Chongqing University of Technology),Ministry of Education(No.2018KLMT03)Materials Science and Engineering provincial-level superior discipline funding project of Xi'an Shiyou Universitythe Program for Young Innovative Research Team in Xi'an Shiyou University(No.2015QNKYCXTD02)。
文摘Because of the complex constraint effects among layers in multi-layered metallic bellows hydroforming,the stress concentration and defects such as wrinkling and fracture may easily occur.It is a key to reveal the deformation behaviors in order to obtain a sound product.Based on the ABAQUS platform,a 3 D-FE model of the four-layered U-shaped metallic bellow hydroforming process is established and validated by experiment.The stress and strain distributions,wall thickness variations and bellow profiles of each layer in the whole process,including bulging,folding and springback stages,are studied.Then deformation behaviors of bellows under different forming conditions are discussed.It is found that the wall thinning degrees of different layer vary after hydroforming,and is the largest for the inner layer and smallest for the outer layer.At folding stage,the wall thinning degree of the crown point increases lineally,and the difference among layers increases as the process going.The displacements of the crown point decrease from the inner layer to the outer layer.After springback,the U-shaped cross section changes to a tongue shape,the change of convolution pitch is much larger than the change of convolution height,and the springback values of the inner layer are smaller than the outer layer.An increase in the internal pressure and die spacing cause the maximum wall thinning degree and springback increase.With changing of process parameters,bellows with deep convolution are easily encountered wall thinning during hydroforming and convolution distortion after springback.This research is helpful for precision forming of multi-layered bellows.
文摘In order to reduce high calibration pressure in hydroforming of components with too small radii, a method wasproposed to manufacture automotive hollow components with rectangular shape by relatively lower pressure. Theprocess is simulated and analyzed. It is thought that the friction force between the die surface and tube is a mainreason that high pressure is needed to form small radii. Using the method proposed in this paper, a petal-like sectionshape is first preformed so that the central zones of the four sides of the preform section do not contact with the diesides, thus the tube metal is easy to flow into the transition radii area in calibration stage. Moreover, a positive forcealong the sides is produced by the internal pressure, which is beneficial to overcome the friction force and push thematerial into the radii. Therefore, the pressure for forming the transition radii is greatly reduced and the componentswith small radii can be formed with relatively lower pressure. For the experimental case conducted in this paper, theforming pressure is reduced by about 28.6% than the estimated forming pressure.
基金supported by grants-in-aid for the National Core Research Center Program from MEST/KOSEF
文摘The friction coefficient between tube and die in guide zone of tube hydroforming was obtained. In hydroforming, the tube is expanded by an internal pressure against the tool wall. By pushing the tube through tool, a friction force at the contact surface between the tube and the tool occurs. In guiding zone, the friction coefficients between tube and die can be estimated from the measured axial feeding forces. In expansion zone, the friction coefficients between tube and die can be evaluated from the measured geometries of expanded tubes and FE analysis.
文摘The uniaxial tensile test of the 5A06-O aluminium−magnesium(Al−Mg)alloy sheet was performed in the temperature range of 20−300℃ to obtain the true stress−true strain curves at different temperatures and strain rates.The constitutive model of 5A06-O Al−Mg alloy sheet with the temperature range from 150 to 300℃ was established.Based on the test results,a unique finite element simulation platform for warm hydroforming of 5A06-O Al−Mg alloy was set up using the general finite element software MSC.Marc to simulate warm hydroforming of classic specimen,and a coupled thermo-mechanical finite element model for warm hydroforming of cylindrical cup was built up.Combined with the experiment,the influence of the temperature field distribution and loading conditions on the sheet formability was studied.The results show that the non-isothermal temperature distribution conditions can significantly improve the forming performance of the material.As the temperature increases,the impact of the punching speed on the forming becomes particularly obvious;the optimal values of the fluid pressure and blank holder force required for forming are reduced.
基金This project is supported by Doctoral Fundation of China(No.20010487002) and Municipal Key Technology R&D Program of Guangzhou, China(No, 2002Z3-0211).
文摘The study of multipoint blank holder force（BHF） control is carried out for hydroforming a complicated shape motorcycle fuel tank. By finite element method （FEM） simulation, the configuration of multipoint blank holder cylinders and the setting of local BHF are optimized, and the influences of the multipoint BHF on the hydromechanical deep drawing and conventional hydroforming processes are studied. The desired fluid pressure and whole BHF are predicted for hydromechanical deep drawing process. Finally, simulation results are testified by forming experiment, and they are in agreement very well.
基金Projects(50525516, 50875062 ) supported by the National Natural Science Foundation of China
文摘A new process of hydroforming with controllable radial pressure was proposed to overcome difficulties in the forming of low plastic materials and large height-to-diameter ratio workpieces. A typical 5A06 aluminum alloy dome was numerically and experimentally investigated. The reasons for typical defects were analyzed under different radial pressures. Effects of radial pressure on the thickness distribution were discussed and optimal radial pressure was determined. It is shown by numerical simulations and experiment that a cup with a drawing ratio of 2.4 is formed by the new process of hydroforming with controllable radial pressure. It is significantly effective for the forming of low plastic materials and large height-to-diameter ratio workpieees. Two typical thinning points exit along the dome wall. With the radial pressure, thinning is decreased effectively at the two points, the dome forming is achieved and thickness distribution is more uniform.
基金Project(NCET-07-0237)supported by the Program for New Century Excellent Talents in University,China
文摘In tube hydroforming with axial feeding,under the effect of coupled internal pressure and axial stress,wrinkles often occur and affect the forming results.Wrinkling behavior of an AZ31B magnesium alloy tube was experimentally investigated with different loading paths at different temperatures.Features of wrinkles,including shape,radius and width,were acquired from the experiments,as well as the thickness distribution.Numerical simulations were carried out to reveal the stress state during warm hydroforming,and then the strain history of material at the top and bottom of the wrinkles were analyzed according to the stress tracks and yielding ellipse.Finally,effects of loading paths on expansion ratio limit of warm hydroforming were analyzed.It is verified that at a certain temperature,expansion ratio limit can be increased obviously by applying a proper loading path and realizing enough axial feeding.
基金Funded by the National Natural Science Foundation of China(50525516)
文摘The hydroforming experiment of aluminum tubular part with rectangular section was carried out to investigate influence of axial feeding on thickness distribution and calibration pressure of the corner.Thickness distribution and relation between corner radius and internal pressure were analyzed.The influence of lubricant was discussed.Microstructure and hardness of different region were observed.It is shown that thickness reduction in the transition region between the corner and center region is the biggest.Friction condition has influence both on the thickness distribution and calibration pressure of the corner.As the increase of the axial feeding,the calibration pressure is decreased.There is only little change for the microstructure,but the hardness is increased by 23.3% for the transition region.
文摘Tube hydroforming process is a relative new process f or production of structural parts of low weight and high rigidity. The successfu lness of the process depends largely on the a proper selection of loading path w hich is axial feeding distance as related to the applied internal pressure. Due to the complicated nature of plastic deformation, a optimum loading path which w ill guarantee good hydroformed parts free of winkle and fracture has often to be determined by finite element analysis. In order to save trials and errors, adap tive FEM simulation method has been developed. To effectively apply the adaptive simulation method, we have to know the applicability of the method. In this pap er, a classification of tube hydroforming (THF) processes based on sensitivity to loading parameters has been suggested. Characteristics of the classification have been analyzed in terms of failure mode, dominant loading parameters and th eir working windows. It was discussed that the so called pressure dominant THF p rocess is the most difficult process for both simulation in FEM analysis and pra ctical operation in real manufacturing situation. To effectively find out the op timum loading path for pressure dominant THF process, adaptive FEM simulation st rategies are mostly needed.
文摘Advanced high strength steels are the group of material with high strength and good formability, because high strength lesser gauge thickness can be used without compromising the function of component. In terms of economic forming process, hydroforming is the manufacturing option which uses a fluid medium to form a component by using high internal pressure. This process gained steep interest in the automotive and aerospace industries because of its many advantages such as part consolidation, good quality of the formed part etc. The main advantage is that the uniform pressure can be transferred to whole projected part at the same time. Low pressure tube hydroforming considered an inexpensive option for forming these advanced high strength steel. This paper investigates the pressurization system used during the low pressure tube hydroforming cycle. It is observed that the usage of ramp pressure cycle during forming the part from low pressure tube hydroforming results in lesser die holding force. Also, the stress, strain and thickness distribution of the part during low pressure tube hydroforming are critically analysed.
基金Project(2006BAE04B03)supported by the National S&T Support Program for The 11th Five-year Plan。
文摘The effects of temperature on the mechanical properties and elongation of AZ61A tubular part were derived by uni-axial tension tests at various temperatures.Warm hydroforming of an AZ61A tubular part for passenger car was then numerically and experimentally investigated.The complete processes including bending,pre-forming and hydroforming were analyzed and discussed. Microstructure at the corner of the typical section was observed before and after the final hydroforming process.It is shown that the yielding strength,tensile strength and total elongation increase as temperature increases,while the elongation before necking decreases.The temperature range from 225℃to 250 ℃is more suitable for hydroforming of theAZ61A magnesium alloy tube with various cross sections.Pre-forming and hydroforming with high strain values are feasible at elevated temperature.Grain refinement is observed at the corner of the part after warm hydroforming.Thinning ratio analysis illustrates that non-uniform deformation at elevated temperature should be considered in process optimization to avoid severe local thinning.
基金This work is supported by the National Natural Science Foundation under grant No.59975021,which was gratefully acknowledged.At the same time,the author also thanks Prof.P.Zeng of Tsinghua University for his kind assistance which is also indispensble in the accomplishment of this paper.
文摘The internal pressure of the process was studied theoretically and experimentally. The external load character and internal stress character of tube hydroforming were discussed first. Then, according to the characters, the function and classification of internal pressure were presented in general. Base on the stress analysis, its effect on the yield criterion and calculation formula were also researched and derived. To verify the correction of the theoretical analysis and derived formula, experiments with different internal pressures were carried out and the result was compared and discussed. It demonstrates that internal pressure plays an important role in tube hydroforming and theory and formula discussed and derived by this paper are feasible in practice.
基金co-supported by the International Cooperation of RFBR-NSFC (No. 51111120088)the financial support from the National Natural Science Foundation of China (No. 50975014)
文摘To obtain the influence of fluid pressure and temperature on warm hydroforming of 5A06-O aluminum alloy sheet, the unified mechanics equilibrium equations, which take through- thickness normal stress and friction into account, were established in spherical coordinate system. The distribution of through-thickness normal stress in the thickness direction was determined. The relation between through-thickness normal stress and fluid pressure was also analyzed in different regions of cylindrical cup. Based on the method of subtracting one increasing function from another, the constitutive equation of 5A06-O applied to warm hydroforming was established and in a good agreement with uniaxial tensile data. Based on whether the thickness variation was taken into account, two mechanic models were established to do the comparative study. The results for the studied case show that the calculated stress values are pretty close according to the two models and consistent with results of finite element analysis; the thickness distribution in flange computed by the second model conforms to the experimental data. Finally, the influences of fluid pressure on the flange thickness and radial stress were analyzed.
基金Supported by the National Key Technology R&D Program of the 11th Five-Year Plan of China(2006BAF04B05)the Natural Science Foundation of Shanxi Province(2010021024-2)
文摘Perfect combination of structural size parameters of the hydroforming billets is essential to obtain even wall thicknesses of the car beam. Finite element （ FE ） analysis on hydroforming car beam was carried out, and the results were optimized according to multiple quality objectives by the grey system theory. With bending angle, bending radius and hight difference along the axis direction as variables, orthogonal FE analyses were conducted and the minimum and maximum wall thicknes ses of the billets with different sizes were obtained. Taking the minimum and maximum wall thick nesses as two references, the correlation coefficient between the data for reference and those for comparison by the grey system theory reduced multi objectives to a single quality objective, and the average correlation level of every billet facilitated the optimization of size parameters for hydroform ing car beam. The trial production showed that the optimization approach satisfied the need of hy droforming car beams.
文摘An investigation was conducted on how to control loading path and its effect on thickness distribution after hydroforming crankshaft by using finite element simulation. Four different loading paths were utilized in simulating the forming process of hydroforming crankshaft and the results of different loading paths were presented. It shows that the hydroforming is dependent on the appropriate loading path. There exists the zone of hydroforming process window which can be confirmed by using simulation method. Wrinkles occur as the the internal pressure is less than 20MPa and bursting occurs as the the internal pressure is larger than 32MPa. Only when the internal pressure locates between 20MPa and 30MPa, can an eligible crankshaft component be manufactured.
基金This project is supported by National Science and Technology Foundation of China (No.96-918-02-03).
文摘A new hydroforming process for manufacturing corrosion-resistant-alloy(CRA)-lined pipe is proposed to overcome the disadvantages in existing technologies, and a new kindof hydraulic expansion device for bimetallic CRA-lined pipe has been researched and developed. Itsoperational principal and technical characteristic is also introduced. The stress and strain in theliner and outer pipe during the hydroforming process have been analyzed and the mechanism ofhydraulic expansion method is studied theoretically. The final forming pressure formula is suggestedand the theoretical analysis is verified by experimental investigation. The results indicate thatthe new technology is feasible and can be applied in industrial production.
基金Sponsored by the National Natural Science Foundation of China(Grant No.U0934006)
文摘According to characteristic of hydroforming of parallel multi-branch tubes,multi-objective problems were transformed to single objective problem of relational grade comparison by grey system theory.Two different objectives were selected,according to the principle that process parameters were optimal which of grey relational grade were maximum,the optimal loading parameters under different objective condition were obtained,and loading paths were optimized.The results indicated that parallel multi-branch tubes hydroformed under loading paths optimized by grey system theory could meet with the requirement that objective was optimal.And the optimal loading paths under different objectives were different,and the appropriate objective should be selected according to forming characteristic.
基金Project(NCET-07-0237) supported by New Century Excellent Talents Program in Chinese University
文摘Process of warm tube hydroforming was experimentally investigated for forming an AZ31B magnesium alloy tubular part with a large expansion ratio. Effects of temperature on the mechanical properties and formability were studied by uniaxial tensile test and hydraulic bulge test. Total elongation increases with temperature up to 250℃, but uniform elongation and maximum expansion ratio get the highest value at 175℃. Different axial feeding amounts were applied in experiments to determine the reasonable loading path. A preform with useful wrinkles was then realized and the tubular part with an expansion ratio of 50% was formed. Finally, mechanical condition to produce useful wrinkles is deduced and the result illustrates that useful wrinkles are easier to be obtained for tube with higher strain hardening coefficient value and tubular part with smaller expansion ratio.
基金Projects(51005054, 50575051) supported by the National Natural Science Foundation of ChinaProject(HIT.BRETI.2010010) supported by the Fundamental Research Funds for the Central Universities, ChinaProject(20100471025) supported by the National Science Foundation for Post-doctoral Scientists of China
文摘Both experimental and mechanical analyses were carded out to investigate the characteristics of thickness distribution for tailor-welded tube （TWT） hydroforming with dissimilar thickness. Then, the effects of weld-seam position and thickness difference were also revealed. A multiple-diameter tube was formed to reveal the characteristics and the regularity of thickness distribution during TWT hydroforming. It is indicated that there are obvious fluctuations in thickness distribution though the TWTs have the same expansion ratio. The thinning ratio of thinner tube is bigger than that of thicker tube especially in the zone closed to the weld-seam. The difference in thinning ratio between two tube segments can reach 9%. Consequently, sudden and large fluctuation of thickness appears in the zone nearby the weld-seam. The difference in thinning ratio between thinner and thicker tubes enlarges as the thickness difference increases, but improves as length ratio increases. Different strain states are the main reason to induce nonuniform thickness distribution. The difference in thickness is the main reason to induce different strain states on thinner and thicker tubes.
