A low-carbon TRIP seamless steel tube, which is expected to be used in the hydroforming process, was successfully fabricated using piercing, cold-drawing and two-stage heat treatment process. The two-stage heat treatm...A low-carbon TRIP seamless steel tube, which is expected to be used in the hydroforming process, was successfully fabricated using piercing, cold-drawing and two-stage heat treatment process. The two-stage heat treatment is one crucial step because it significantly affects the microstructure and mechanical properties of TRIP seam less steel tube. In order to obtain the TRIP seamless steel tube with high hydroformability, several different heat treatment processes were conducted. The effects of heat treatment conditions （intercritical annealing （IA） and isothermal bainite treatment （IBT）） on the TRIP seamless steel tube hydroformability which was determined by free hydraulic bulge test were analyzed. Two different internal pressure boosting velocities of 0.2 and 0.5 MPa/s of free hydraulic bulge tests were adopted to determine the effective stress vs. effective strain curve of TRIP seamless steel tube. The results showed that for the predetermined IA condition, the maximum bulge height increased, but the maximum burst internal pressure decreased, with the increase of IBT holding time from 4 to 6 rain. For the predetermined IBT condition, the maximum bulge height decreased, but the maximum burst internal pressure increased, with the increase of IA holding time from 5 to 10 rain. By analyzing the free hydraulic bulge test results, it was found that the maximum bulge heights of TRIP seamless steel tubes with the internal pressure boosting velocity of 0.5 MPa/s were higher than those when the internal pressure boosting velocity was 0.2 MPa/s. This means that an appropriate deformation rate should be chosen to obtain the optimal hydroformability of TRIP seamless steel tube. In addition, the effective stress vs. effective strain curves of TRIP seamless steel tubes were ohtained with free hydraulic bulge test.展开更多
The design of the loading path is one of the important research contents of the tube hydroforming process.Optimization of loading paths using optimization algorithms has received attention due to the inefficiency of o...The design of the loading path is one of the important research contents of the tube hydroforming process.Optimization of loading paths using optimization algorithms has received attention due to the inefficiency of only finite element optimization.In this paper,the hydroforming process of 5A02 aluminum alloy variable diameter tube was as the research object.Fuzzy control was used to optimize the loading path,and the fuzzy rule base was established based on FEM.The minimum wall thickness and wall thickness reduction rate were determined as input membership functions,and the axial feeds variable value of the next step was used as output membership functions.The results show that the optimized loading path greatly improves the uniformity of wall thickness and the forming effect compared with the linear loading path.The round corner lamination rate of the tube is 91.2%under the fuzzy control optimized loading path,which was increased by 47.1%and 22.6%compared with linear loading Path 1 and Path 2,respectively.Based on the optimized loading path in the experiment,the minimum wall thickness of the variable diameter tube was 1.32 mm and the maximum thinning rate was 12.4%.The experimental results were consistent with the simulation results,which verified the accuracy of fuzzy control.The research results provide a reference for improving the forming quality of thin-walled tubes and plates.展开更多
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
Ring hoop tension test and tube bulging test were carried out at elevated temperatures up to 480 ℃to evaluate the formability of AZ31B extruded tube for internal high pressure forming （IHPF） process. The total elon...Ring hoop tension test and tube bulging test were carried out at elevated temperatures up to 480 ℃to evaluate the formability of AZ31B extruded tube for internal high pressure forming （IHPF） process. The total elongation along hoop direction and the maximum expansion ratio （MER） of the tube were obtained. The fracture surface after bursting was also analyzed. The results show that the total elongation along hoop direction and the MER value have a similar changing tendency as the testing temperature increases, which is quite different from the total elongation along axial direction. Both the total elongation along hoop direction and the MER value increase to a peak value at about 160 ℃. After that, they begin to decrease quickly until a certain rebounding temperature is reached. From the rebounding temperature, they begin to increase rapidly again. Burnt structure appears on the fracture surface when tested at temperatures higher than 420 ℃. Therefore, the forming temperature of the tested tube should be lower than 420 ℃, even though bigger formability can be achieved at higher temperature.展开更多
Single-atom catalysis,the catalysis by single-atom catalysts(SACs),has attracted considerable attention in recent years as a new frontier in the heterogeneous catalysis field.SACs have the advantages of both homogeneo...Single-atom catalysis,the catalysis by single-atom catalysts(SACs),has attracted considerable attention in recent years as a new frontier in the heterogeneous catalysis field.SACs have the advantages of both homogeneous catalysts(isolated active sites)and heterogeneous catalysts(stable and easy to separate),and are thus predicted to be able to bridge the homo-and heterogeneous catalysis.This prediction was first experimentally demonstrated in 2016.In this mini-review,we summarize the few homogeneous catalysis progresses reported recently where SACs have exhibited promising application:a)Rh/ZnO and Rh/CoO SAC have been used successfully in hydroformylation of olefin of which the activity are comparable to the homogeneous Wilkinson’s catalyst;b)a Pt/Al2O3 SAC has shown excellent performance in hydrosilylation reaction;and c)M-N-C SACs(M=Fe,Co etc.)have been applied in the activation of C–H bonds.All of these examples suggest that fabrication of suitable SACs could provide a new avenue for the heterogenization of homogeneous catalysts.These pioneering works shed new light on the recognition of single-atom catalysis in bridging the homo-and heterogeneous catalysis.展开更多
A new generation of fluid pressure forming technology has been developed for the three typical structures of tubes,sheets,and shells,and hard-to-deform material components that are urgently needed for aerospace,aircra...A new generation of fluid pressure forming technology has been developed for the three typical structures of tubes,sheets,and shells,and hard-to-deform material components that are urgently needed for aerospace,aircraft,automobile,and high-speed train industries.in this paper,an over all review is introduced on the state of the art in fundamentals and processes for lower-pressure hydroforming of tubular components,double-sided pressure hydroforming of sheet components,die-less hydroforming of ellipsoidai shells,and dual hardening hot medium forming af hard-to-deform materiais Particular attention is paid to deformation behavior,stress state adjustment,defect prevention,and typical applications.In addition,future development directions of fluid pressure forming technology are discussed,including hyper lower-loading forming for ultra-large non-uniform components,precision for ming for intermetallic compound and high-entropy alloy components,intelligent process and equipment,and precise finite element simulation of inhomogeneous and strong anisotropic thin shells.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 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 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
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 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
In order to meet the requirements of high reliability,long-lifetime and lightweight in a new generation of aerospace,aviation,high-speed train,and energy power equipment,integrated components are urgently needed to re...In order to meet the requirements of high reliability,long-lifetime and lightweight in a new generation of aerospace,aviation,high-speed train,and energy power equipment,integrated components are urgently needed to replace traditional multi-piece,welded components.The applications of integrated components involve in a series of large-size,complex-shaped,highperformance components made of difficult-to-deform materials,which present a huge challenge for forming ultra-large size integrated components.In this paper,the developments and perspectives of several extreme forming technologies are reviewed,including the sheet hydroforming of ultra-large curved components,dieless hydroforming of ellipsoidal shells,radial-axial ring rolling of rings,in situ manufacturing process of flanges,and local isothermal forging of titanium alloy components.The principle and processes for controlling deformation are briefly illustrated.The forming of typical ultra-large size integrated components and industrial applications are introduced,such as the high strength aluminum alloy,3m in diameter,integrated tank dome first formed by using a sheet blank with a thickness the same as the final component,and a 16m diameter,integrated steel ring rolled by using a single billet.The trends for extreme forming of ultra-large size integrated components are discussed with a goal of providing ideas and fundamental guidance for the further development of new forming processes for extreme-size integrated components in the future.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
In this paper, an aeronautical thin-walled part with a complex geometry which has several sharp bends and curvatures in different directions was investigated. This kind of part is difficult to be manufactured only in ...In this paper, an aeronautical thin-walled part with a complex geometry which has several sharp bends and curvatures in different directions was investigated. This kind of part is difficult to be manufactured only in one stage. Therefore, an innovative multi-stage active hydroforming process assisted by the rigid forming method was designed. In addition, an optimized blank geometry is obtained. In fact, the main focused point of this paper is to propose a new small radius rounded corner forming technique and analyze the mechanism. Two kinds of forming modes of changing a big rounded corner into a small one, which are related to different tangential positions of the die in the process of calibration, are analyzed theoretically. Meanwhile, the stress and strain states of the deformation region are compared. The relationships between the minimum relative radii of rounded corners I and II in the first stage and the hydraulic pressure are calculated by the bending theory. Finally, the influences of the tensile-bulging effect and the interface condition of the double-layer sheet on the forming quality of the specimen are investigated. The achieved results can make a foundation for utilizing the proposed method in forming of thin-walled parts with very small radii.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
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
基金Item Sponsored by National Natural Science Foundation of China(51304046)Grant-in-Aid for Young Scientists (B) of Japan Society for the Promotion of Science(25870594)+2 种基金Fundamental Research Funds for the Central Universities of China(N130403013)Specialized Research Fund for the Doctoral Program of Higher Education of China(20130042120031)Scientific Research Starting Foundation for Introduced Talents of Northeastern University of China(02090021233002)
文摘A low-carbon TRIP seamless steel tube, which is expected to be used in the hydroforming process, was successfully fabricated using piercing, cold-drawing and two-stage heat treatment process. The two-stage heat treatment is one crucial step because it significantly affects the microstructure and mechanical properties of TRIP seam less steel tube. In order to obtain the TRIP seamless steel tube with high hydroformability, several different heat treatment processes were conducted. The effects of heat treatment conditions （intercritical annealing （IA） and isothermal bainite treatment （IBT）） on the TRIP seamless steel tube hydroformability which was determined by free hydraulic bulge test were analyzed. Two different internal pressure boosting velocities of 0.2 and 0.5 MPa/s of free hydraulic bulge tests were adopted to determine the effective stress vs. effective strain curve of TRIP seamless steel tube. The results showed that for the predetermined IA condition, the maximum bulge height increased, but the maximum burst internal pressure decreased, with the increase of IBT holding time from 4 to 6 rain. For the predetermined IBT condition, the maximum bulge height decreased, but the maximum burst internal pressure increased, with the increase of IA holding time from 5 to 10 rain. By analyzing the free hydraulic bulge test results, it was found that the maximum bulge heights of TRIP seamless steel tubes with the internal pressure boosting velocity of 0.5 MPa/s were higher than those when the internal pressure boosting velocity was 0.2 MPa/s. This means that an appropriate deformation rate should be chosen to obtain the optimal hydroformability of TRIP seamless steel tube. In addition, the effective stress vs. effective strain curves of TRIP seamless steel tubes were ohtained with free hydraulic bulge test.
基金supported by the Shenyang Science and Technology Program(grant number 22-301-1-10).
文摘The design of the loading path is one of the important research contents of the tube hydroforming process.Optimization of loading paths using optimization algorithms has received attention due to the inefficiency of only finite element optimization.In this paper,the hydroforming process of 5A02 aluminum alloy variable diameter tube was as the research object.Fuzzy control was used to optimize the loading path,and the fuzzy rule base was established based on FEM.The minimum wall thickness and wall thickness reduction rate were determined as input membership functions,and the axial feeds variable value of the next step was used as output membership functions.The results show that the optimized loading path greatly improves the uniformity of wall thickness and the forming effect compared with the linear loading path.The round corner lamination rate of the tube is 91.2%under the fuzzy control optimized loading path,which was increased by 47.1%and 22.6%compared with linear loading Path 1 and Path 2,respectively.Based on the optimized loading path in the experiment,the minimum wall thickness of the variable diameter tube was 1.32 mm and the maximum thinning rate was 12.4%.The experimental results were consistent with the simulation results,which verified the accuracy of fuzzy control.The research results provide a reference for improving the forming quality of thin-walled tubes and plates.
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Project(50805033)supported by the National Natural Science Foundation of ChinaProject(E200804)supported by the Natural Science Foundation of Heilongjiang Province of China
文摘Ring hoop tension test and tube bulging test were carried out at elevated temperatures up to 480 ℃to evaluate the formability of AZ31B extruded tube for internal high pressure forming （IHPF） process. The total elongation along hoop direction and the maximum expansion ratio （MER） of the tube were obtained. The fracture surface after bursting was also analyzed. The results show that the total elongation along hoop direction and the MER value have a similar changing tendency as the testing temperature increases, which is quite different from the total elongation along axial direction. Both the total elongation along hoop direction and the MER value increase to a peak value at about 160 ℃. After that, they begin to decrease quickly until a certain rebounding temperature is reached. From the rebounding temperature, they begin to increase rapidly again. Burnt structure appears on the fracture surface when tested at temperatures higher than 420 ℃. Therefore, the forming temperature of the tested tube should be lower than 420 ℃, even though bigger formability can be achieved at higher temperature.
基金supported by National Natural Science Foundation of China(21606222,21776270)Postdoctoral Science Foundation(2017M621170,2016M601350)~~
文摘Single-atom catalysis,the catalysis by single-atom catalysts(SACs),has attracted considerable attention in recent years as a new frontier in the heterogeneous catalysis field.SACs have the advantages of both homogeneous catalysts(isolated active sites)and heterogeneous catalysts(stable and easy to separate),and are thus predicted to be able to bridge the homo-and heterogeneous catalysis.This prediction was first experimentally demonstrated in 2016.In this mini-review,we summarize the few homogeneous catalysis progresses reported recently where SACs have exhibited promising application:a)Rh/ZnO and Rh/CoO SAC have been used successfully in hydroformylation of olefin of which the activity are comparable to the homogeneous Wilkinson’s catalyst;b)a Pt/Al2O3 SAC has shown excellent performance in hydrosilylation reaction;and c)M-N-C SACs(M=Fe,Co etc.)have been applied in the activation of C–H bonds.All of these examples suggest that fabrication of suitable SACs could provide a new avenue for the heterogenization of homogeneous catalysts.These pioneering works shed new light on the recognition of single-atom catalysis in bridging the homo-and heterogeneous catalysis.
基金supported by the National Science Fund for Distinguished Young Scholars(50525516)the National Natural Science Foundation of China(U1637209,51175111,50375036,and 59975021).
文摘A new generation of fluid pressure forming technology has been developed for the three typical structures of tubes,sheets,and shells,and hard-to-deform material components that are urgently needed for aerospace,aircraft,automobile,and high-speed train industries.in this paper,an over all review is introduced on the state of the art in fundamentals and processes for lower-pressure hydroforming of tubular components,double-sided pressure hydroforming of sheet components,die-less hydroforming of ellipsoidai shells,and dual hardening hot medium forming af hard-to-deform materiais Particular attention is paid to deformation behavior,stress state adjustment,defect prevention,and typical applications.In addition,future development directions of fluid pressure forming technology are discussed,including hyper lower-loading forming for ultra-large non-uniform components,precision for ming for intermetallic compound and high-entropy alloy components,intelligent process and equipment,and precise finite element simulation of inhomogeneous and strong anisotropic thin shells.
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.
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.
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This work was funded in part by the National Key Research and Development Program of China(2017YFB0306304)the National Natural Science Foundation of China(51705102,U1637209).The authors wish to express their gratitude for the funding.
文摘In order to meet the requirements of high reliability,long-lifetime and lightweight in a new generation of aerospace,aviation,high-speed train,and energy power equipment,integrated components are urgently needed to replace traditional multi-piece,welded components.The applications of integrated components involve in a series of large-size,complex-shaped,highperformance components made of difficult-to-deform materials,which present a huge challenge for forming ultra-large size integrated components.In this paper,the developments and perspectives of several extreme forming technologies are reviewed,including the sheet hydroforming of ultra-large curved components,dieless hydroforming of ellipsoidal shells,radial-axial ring rolling of rings,in situ manufacturing process of flanges,and local isothermal forging of titanium alloy components.The principle and processes for controlling deformation are briefly illustrated.The forming of typical ultra-large size integrated components and industrial applications are introduced,such as the high strength aluminum alloy,3m in diameter,integrated tank dome first formed by using a sheet blank with a thickness the same as the final component,and a 16m diameter,integrated steel ring rolled by using a single billet.The trends for extreme forming of ultra-large size integrated components are discussed with a goal of providing ideas and fundamental guidance for the further development of new forming processes for extreme-size integrated components in the future.
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supported by the National Science and Technology Major Project of China (No. 2014ZX04002041)
文摘In this paper, an aeronautical thin-walled part with a complex geometry which has several sharp bends and curvatures in different directions was investigated. This kind of part is difficult to be manufactured only in one stage. Therefore, an innovative multi-stage active hydroforming process assisted by the rigid forming method was designed. In addition, an optimized blank geometry is obtained. In fact, the main focused point of this paper is to propose a new small radius rounded corner forming technique and analyze the mechanism. Two kinds of forming modes of changing a big rounded corner into a small one, which are related to different tangential positions of the die in the process of calibration, are analyzed theoretically. Meanwhile, the stress and strain states of the deformation region are compared. The relationships between the minimum relative radii of rounded corners I and II in the first stage and the hydraulic pressure are calculated by the bending theory. Finally, the influences of the tensile-bulging effect and the interface condition of the double-layer sheet on the forming quality of the specimen are investigated. The achieved results can make a foundation for utilizing the proposed method in forming of thin-walled parts with very small radii.
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(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.
