Experimental Study of Hydroformed Al6061T4 Elliptical Tube Samples under Different Internal Pressures

In order to achieve crack free elliptical shape under controlled conditions, an experimental set-up was designed and fabricated. This setup consists of three hydraulic cylinders, an intensifier, a hydraulic power pack, storage tanks, forming die, and all parts are controlled by a Programmable Logic Controller (PLC) system. The elliptical samples can be achieved through proper control of internal pressure and axial force with proper sealing. Experimental work has been carried out with different magnitudes of internal pressure and constrained conditions of axial force. Initially die of elliptical shape has been designed and modeled in Abaqus to successfully achieve the particular shape of the Al6061T4 tube under different internal pressure. The fabricated tube hydroforming machine set-up is highly effective for forming 0.5 mm-2 mm thick Al6061T4 alloy tube samples. The Experimental test has been carried out at 12.7 mm outer diameter, 175 mm length and 0.5 mm thick Al6061T4 samples. Bulge height parameters measured at different points of regular distance gap on the axial direction of the tube length and corner radius found at different pressures range of the samples are plotted under different internal pressures. Samples having an 18.7 mm major elliptical bulge were achieved during the experiment. The experimental data was validated by simulation results

Latest Hydroforming Technology of Metallic Tubes and Sheets

This Special Issue and Book, ‘Latest Hydroforming Technology of Metallic Tubes and Sheets’, includes 16 papers, which cover the state of the art of forming technologies in the relevant topics in the field. The technologies and methodologies presented in these papers will be very helpful for scientists, engineers, and technicians in product development or forming technology innovation related to tube hydroforming processes

Forming-based geometric correction methods for thin-walled metallic components:a selective review

Geometric correction processes contribute to zero-defect manufacturing for improved product quality. Thin-walled metallic components are widely used in numerous applications such as electric vehicles and aircraft due to the lightweight feature, facilitating to achieve zero-emission goals. However, many components suffer geometric imperfections and inaccuracies such as undesired curvatures and twists, seriously affecting subsequent manufacturing operations, for example, automatic welding and assembly. Geometric correction techniques have been established to address these issues, but they have drawn little attention in the scientific community despite their wide applications and urgent demands in the industry. Due to the strict geometric tolerances demanded in high-volume automated production, it is urgent to increase the knowledge needed to develop new techniques to address future industrial challenges. This review paper presents an overview of typical geometric defects in thin-walled components and clarifies the associated underlying generation mechanisms. Attempts have also been made to discuss and categorize geometric correction techniques based on different forming mechanisms. The challenges in correcting complex thin-walled products are discussed. This review paper also provides researchers and engineers with directions to find and select appropriate geometric correction methods to achieve high geometric accuracy for thin-walled metallic components.</p

Computer aided design and optimization of bi-layered tube hydroforming process

Tube hydroforming is one of the unconventional metal forming processes in which high fluid pressure and axial feed are used to deform a tube blank in the desired shape. However, production of bi-layered tubular components using this process has not been investigated in detail in spite of the large number of research studies conducted in this area. Bi-layered tubing can be useful in complex working environments as it offers dual properties that a single layer structure doesn’t have. Consequently, for wider implementation of this technology, a detailed investigation on bi-layered tube hydroforming is required. In this research, both single and bi-layered tube hydroforming processes were numerically modelled using the finite element method (ANSYS LS-DYNA). Experiments were conducted to check the numerical models validation. In addition, Response Surface Methodology (RSM) using the Design-Expert statistical software has been employed along with the finite element modelling to attain a detailed investigation of bi-layered tube hydroforming in the X-type and T-type dies. The process outputs were modelled as functions of both the geometrical factors (tube length, tube diameter, die corner radius, and thicknesses of both layers.) and the process parameters (internal pressure coordinates, axial feed, and coefficient of friction.). Furthermore, the desirability approach was used in conjunction with the RSM models to identify the optimal combinations of each the geometrical factors and process parameters that achieve different objectives simultaneously. In addition, a different optimization approach that applies the iterative optimization algorithm in the ANSYS software was implemented in the process optimization. The finite element models of single and bi-layered tube hydroforming processes were experimentally validated. A comparison of both processes was carried out under different loading paths. Also, response surface modelling of the bi-layered tube hydroforming process outputs was successfully achieved, and the main effects and interaction effects of the input parameters on the responses were discussed. Based on the RSM models, the process was optimized by finding the inputs levels at which the desired objectives are satisfied. Finally, a comparison of the RSM based optimization approach and the iterative optimization algorithm was performed based on the optimum results of each technique

Quality comparison of Y-shape joints by tube hydroforming with and without counterforce

The design capability, strength, and structural rigidity provided by tube hydroforming (THF) are successfully used in many applications to produce high-strength parts and assemblies with improved mechanical properties, optimized service life, and weight features. In tubular metal forming, output parameters such as branch height, distribution of tube wall material thickness, distribution of damage factor, metal flow, effective stress, and effective strain significantly affect the quality of the product after the forming process. Therefore, this paper aims to evaluate the manufacturing quality of Y-shape joints from AISI304 material steel tube through output parameters of THF process with and without counter punch force on numerical simulation base. The Finite Element Method (FEM) has become an established feature of metal forming technology. The objective of FEM is to replace costly and elaborate experimental testing with fast, low-cost computer simulation. The simulation study uses finite element method-based virtual prototyping techniques to characterize output parameters, gain insight into strain mechanics, and predict mechanical properties of shaped components. The research results are presented clearly and unambiguously through the evaluation of 7&nbsp;criteria to compare the quality of the specimens hydroformed by two surveyed cases and optimize the crucial input process parameters. And these data can be applied in experiments, more efficient product and process design, calculation, and control of input parameters avoiding costly trial and error in industrial production. The findings can help technologists optimize process parameters in the hydroforming process of products with protrusion from a tubular blan

High-efficiency forming processes for complex thin-walled titanium alloys components: State-of-the-art and Perspectives

Complex thin-walled titanium alloy components play a key role in the aircraft, aerospace and marine industries, offering the advantages of reduced weight and increased thermal resistance. The geometrical complexity, dimensional accuracy and in-service properties are essential to fulfill the high-performance standards required in new transportation systems, which brings new challenges to titanium alloy forming technologies. Traditional forming processes, such as superplastic forming or hot pressing, cannot meet all demands of modern applications due to their limited properties, low productivity and high cost. This has encouraged industry and research groups to develop novel high-efficiency forming processes. Hot Gas Pressure Forming (HGPF) and hot stamping-quenching technologies have been developed for the manufacture of tubular and panel components, and are believed to be the cut-edge processes guaranteeing dimensional accuracy, microstructure and mechanical properties. This article intends to provide a critical review of high-efficiency titanium alloy forming processes, concentrating on latest investigations of controlling dimensional accuracy, microstructure and properties. The advantages and limitations of individual forming process are comprehensively analyzed, through which, future research trends of high-efficiency forming are identified including trends in process integration, processing window design, full cycle and multi-objective optimization. This review aims to provide a guide for researchers and process designers on the manufacture of thin-walled titanium alloy components whilst achieving high dimensional accuracy and satisfying performance properties with high efficiency and low cost

Computer aided optimization of tube hydroforming processes

Tube hydroforming is a process of forming closed-section, hollow parts with different cross sections by applying combined internal hydraulic forming pressure and end axial compressive loads or feeds to force a tubular blank to conform to the shape of a given die cavity. It is one of the most advanced metal forming processes and is ideal for producing seamless, lightweight, near net shape components.. This innovative manufacturing process offers several advantages over conventional manufacturing processes such as part consolidation, weight reduction and lower tooling and process cost. To increase the implementation of this technology in different manufacturing industries, dramatic improvements for hydroformed part design and process development are imperative. The current design and development of tube hydroforming processes is plagued with long design and prototyping lead times of the component. The formability of hydroformed tubular parts is affected by various physical parameters such as material properties, tube and die geometry, boundary conditions and process loading paths. Finite element simulation is perceived by the industry to be a cost-effective process analysis tool and has the capability to provide a greater insight into the deformation mechanisms of the process and hence allow for greater product and process optimization. Recent advances in the non-linear metal forming simulation capabilities of finite element software have made simulation of many complex hydroforming processes much easier. Although finite element based simulation provides a better understanding of the process, trial-and-error based simulation and optimization becomes very costly for complex processes. Thus, powerful intelligent optimization methods are required for better design and understanding of the process. This work develops a better understanding of the forming process and its control parameters. An experimental study of ‘X ’ and ‘T’-branch type tube hydroforming was undertaken and finite element models of these forming processes were built and subsequently validated against the experimental results. Furthermore these forming processes were optimized using finite element simulations enhanced with numerical optimization algorithms and with an adaptive process control algorithm. These new tools enable fast and effective determination of loading paths optimized for successful hydroforming of complex tubular parts and replace trial-and-error approaches by a more efficient customized finite element analysis approach

Modeling and analysis of dual hydroforming process

The tube hydroforming process has gained increasing attention in recent years. Coordination of the internal pressurization and axial feeding curves is critical in the tube hydroforming process to generate successful parts without fracture or wrinkling failure. The stress state at a given time and location varies with the process history and the design and control of the load paths. A new process parameter, counter-pressure, is introduced to achieve a favorable tri-axial stress state during the deformation process. The new process is referred to as dual hydroforming. The benefits offered by dual hydroforming will be characterized based upon the amount of wall thinning, plastic instability limit and final bulged configuration. An analytical model is developed to analyze the stress and strain state in the part (tube) during the dual hydroforming process. The stress-strain condition analyzed will be used to evaluate and compare thinning for tube hydroforming and dual hydroforming. The effect of applying counter-pressure on the plastic instability of thin-walled tubes with only internal pressure and combination of internal pressure and independent axial loading is considered. Finite element analysis is used to quantify the merits of dual hydroforming in terms of final bulged configuration. A parametric study has been conducted to investigate the effectiveness of dual hydroforming based on the various material properties and process conditions. Dual hydroforming results in different stress and strain states compared to tube hydroforming. The counter-pressure enabled favorable tri-axial stress state during deformation that resulted in different thickness and percentage thinning. Finite element analysis showed that for a particular amount of wall thinning there is an increase of around 8% in bulge height for dual hydroforming. Dual hydroforming delays the onset of plastic instability. This increase in the value of effective strain to failure results in an increase of around 12% in bulge height for dual hydroforming as shown by finite element simulations. Results of this study indicate that dual hydroforming can increase expansion i.e. more difficult parts can be designed and manufactured. Also, for a given part geometry, higher strength and less formable materials can be used

Formability and hydroforming of anisotropic aluminum tubes

textThe automotive industry is required to meet improved fuel efficiency standards and stricter emission controls. Aluminum tube hydroforming is particularly well suited in meeting the goals of lighter, more fuel-efficient and less polluting cars. Its wider use in industry is hindered however by the reduced ductility and more complex constitutive behavior of aluminum in comparison to the steels that it is meant to replace. This study aims to address these issues by improving the understanding of the limitations of the process as applied to aluminum alloys. A series of hydroforming experiments were conducted in a custom testing facility, designed and constructed for the purposes of this project. At the same time, several levels of modeling of the process, of increasing complexity, were developed. A comparison of these models to the experiments revealed a serious deficiency in predicting burst, which was found experimentally to be one of the main limiting factors of the process. This discrepancy between theory and experiment was linked to the adoption of the von Mises yield function for the material at hand. This prompted a separate study, combining experiments and analysis, to calibrate alternative, non-quadratic anisotropic yield functions and assess their performance in predicting burst. The experiments involved testing tubes under combined internal pressure and axial load to failure using various proportional and non-proportional loading paths (free inflation). A number of state of the art yield functions were then implemented in numerical models of these experiments and calibrated to reproduce the induced strain paths and failure strains. The constitutive models were subsequently employed in the finite element models of the hydroforming experiments. The results demonstrate that localized wall thinning in the presence of contact, as it occurs in hydroforming as well as other sheet metal forming problems, is a fully 3D process requiring appropriate modeling with solid elements. This success also required the use of non-quadratic yield functions in the constitutive modeling, although the anisotropy present did not play as profound a role as it did in the simulation of the free inflation experiments. In addition, corresponding shell element calculations were deficient in capturing this type of localization that precipitates failure, irrespective of the sophistication of the constitutive model adopted. This finding contradicts current practice in modeling of sheet metal forming, where the thin-walled assumption is customarily adopted.Aerospace Engineering and Engineering Mechanic