scholarly journals Movable Die and Loading Path Design in Tube Hydroforming of Irregular Bellows

Metals ◽  
2020 ◽  
Vol 10 (11) ◽  
pp. 1518
Author(s):  
Yeong-Maw Hwang ◽  
Yau-Jiun Tsai
Keyword(s):  
Tube Hydroforming ◽  
Simulation Software ◽  
Die Design ◽  
Loading Path ◽  
Feeding Types ◽  
Element Simulation ◽  
Hydroforming Process ◽  
Formed Product ◽  
Loading Path Design ◽  
Deform 3D

Manufacturing of irregular bellows with small corner radii and sharp angles is a challenge in tube hydroforming processes. Design of movable dies with an appropriate loading path is an alternative solution to obtain products with required geometrical and dimensional specifications. In this paper, a tube hydroforming process using a novel movable die design is developed to decrease the internal pressure and the maximal thinning ratio in the formed product. Two kinds of feeding types are proposed to make the maximal thinning ratio in the formed bellows as small as possible. A finite element simulation software “DEFORM 3D” is used to analyze the plastic deformation of the tube within the die cavity using the proposed movable die design. Forming windows for sound products using different feeding types are also investigated. Finally, tube hydroforming experiments of irregular bellows are conducted and experimental thickness distributions of the products are compared with the simulation results to validate the analytical modeling with the proposed movable die concept.

Optimization of Preform for Stub Axle Forging Using Simulation Software

2021 ◽  
Vol 1016 ◽  
pp. 1337-1343
Author(s):  
T. Lachana Dora ◽  
Niranjan Kumar Singh ◽  
Rajkumar Ohdar
Keyword(s):  
Computer Aided Design ◽  
Simulation Software ◽  
Die Design ◽  
Design And Manufacturing ◽  
Cad Cam ◽  
Increase Productivity ◽  
Aided Design ◽  
Preform Shape ◽  
Deform 3D ◽  
Made In

There is a growing demand for more efficient and economic manufacturing process to improve product quality, reduce production cost, reduce lead time and increase productivity. The application of computer aided design and manufacturing (CAD/CAM) techniques to forging is becoming increasingly popular as the resulting improvements in yield and productivity. Modeling and simulation have become a major concern in recent and advanced research. In this paper die design for forging of an automobile component “Stub Axle” is presented. In die forging process, complex shape component cannot be made in one stage and therefore, the use of preform die becomes essential. The initial preform design was carried out by conventional method. The simulation has been carried out using software DEFORM-3D. The main goal of this study is to design an optimal preform shape resulting an optimal initial billet selection. Keywords:CAD/CAM, Preform, DEFORM-3D, Simulation, Forging

A comprehensive damage criterion in tube hydroforming

2020 ◽  
pp. 095440542096296
Author(s):  
Reza Pourhamid ◽  
Ali Shirazi
Keyword(s):  
Damage Model ◽  
Tube Hydroforming ◽  
Material Model ◽  
Vital Role ◽  
Numerical Results ◽  
Loading Path ◽  
Ring Compression Test ◽  
Damage Criterion ◽  
Ring Compression ◽  
Hydroforming Process

In the present study, the Johnson-Cook damage model is proposed as a comprehensive damage criterion to predict all types of probable failures in tube hydroforming process. Also, the Johnson-Cook material model is used to predict the profile of hydroformed tubes and their dimensions. The validity of numerical results was verified using experimental results obtained in this study. Moreover, because of the importance of friction force in this process, existing between the tube and die, the friction coefficient is determined using the ring compression test, separately. The comparison of experimental and numerical results shows that Johnson-Cook damage model can predict all of the possible failures in tube hydroforming process correctly, both in terms of location and loading conditions. And this model does not predict any failure if, the tube is hydroformed perfectly. Additionally, it was cleared that the Johnson-Cook material model is a proper model to predict the profile of hydroformed tubes with remarkable accuracy. Also, it was found that the loading path and creation of a proper wrinkling have a determinative and vital role in the prosperity of the process.

scholarly journals Fabrication Improvement of Cold Forging Hexagonal Nuts by Computational Analysis and Experiment Verification

2015 ◽  
Vol 2015 ◽  
pp. 1-11 ◽  
Author(s):  
Shao-Yi Hsia ◽  
Yu-Tuan Chou
Keyword(s):  
Computer Simulation ◽  
Automobile Industry ◽  
Critical Role ◽  
Simulation Software ◽  
Die Design ◽  
Cold Forging ◽  
Experiment Verification ◽  
Flow Stress Equation ◽  
Deform 3D

Cold forging has played a critical role in fasteners and has been applied to the automobile industry, construction industry, aerospace industry, and living products so that cold forging presents the opportunities for manufacturing more products. By using computer simulation, this study attempts to analyze the process of creating machine parts, such as hexagonal nuts. The DEFORM-3D forming software is applied to analyze the process at various stages in the computer simulation, and the compression test is also used for the flow stress equation in order to compare the differences between the experimental results and the equation that is built into the computer simulation software. At the same time, the metallography and hardness of experiments are utilized to understand the cold forging characteristics of hexagonal nuts. The research results would benefit machinery businesses to realize the forging load and forming conditions at various stages before the fastener formation. In addition to planning proper die design and production, the quality of the produced hexagonal nuts would be more stable to promote industrial competitiveness.

Simulation of Microstructure Evolution on Copper, Aluminum and Alloy during ECAP

2013 ◽  
Vol 652-654 ◽  
pp. 1927-1931
Author(s):  
Ting Biao Guo ◽  
Jun Yuan Zhao ◽  
Yu Tian Ding ◽  
Hai Long Li ◽  
Bo Liu
Keyword(s):  
Microstructure Evolution ◽  
Stacking Fault ◽  
Simulation Software ◽  
Stacking Fault Energy ◽  
Obvious Effect ◽  
Element Simulation ◽  
Metal Aluminum ◽  
Deformation Speed ◽  
Copper Aluminum ◽  
Deform 3D

The microstructure evolution of different stacking fault energy metal materials, copper, aluminum alloy and magnesium alloy during ECAP, were investigated based on the finite element simulation software DEFORM-3D. Analyzed the effect on the microstructure of deformation speed, extrusion passes and stacking fault energy. The results show that, the grain size is decreased with the pass number increasing, and deformation speed has no obvious effect on the microstructure. The high SFE metal, aluminum, shows a finer grains than the medium SFE metal, copper.

The Die Design of Large Diameter Tee Multi-Pass Extrusion Process

2011 ◽  
Vol 194-196 ◽  
pp. 2199-2203
Author(s):  
Jian Zhang ◽  
Tan Li ◽  
Liang Chu ◽  
Da Sen Bi
Keyword(s):  
Large Diameter ◽  
Equivalent Stress ◽  
Extrusion Process ◽  
Equivalent Strain ◽  
Simulation Software ◽  
Die Design ◽  
State Variables ◽  
Element Simulation ◽  
Deformation Stress ◽  
First Contact

Finite element simulation software Deform-3D on large-diameter multi-pass three-way pipe to simulate the extrusion process, the equivalent stress, equivalent strain and load were analyzed. The simulation results show that with the increase of processing pass, deformation process becomes complex, forming more difficult, the value of the state variables are increasing; in the extrusion process, the mold first contact with the billet and extruded convex hull area of the site, compared to other regions, plastic deformation, stress concentration and large, with the mold closed, the force to uniform .The results are well shown that it could provide a theoretical basis to the practical industrial production.

Adaptive Simulations of T-Shape Tube Hydroforming Processes

2007 ◽  
Vol 340-341 ◽  
pp. 627-632 ◽  
Author(s):  
Yeong-Maw Hwang ◽  
Bing Hong Chen ◽  
Wen Chan Chang
Keyword(s):  
Finite Element ◽  
Internal Pressure ◽  
Adaptive Algorithm ◽  
Thickness Distribution ◽  
Tube Hydroforming ◽  
Loading Path ◽  
Finite Element Code ◽  
Simulation Results ◽  
Formed Product ◽  
The Relationship

A successful THF process depends largely on the loading paths for controlling the relationship between the internal pressure, axial feeding and the counter punch. In this study, an adaptive algorithm combined with a finite element code LS-DYNA 3D is proposed to control the simulation of T-shape hydroforming with a counter punch. The effects of the friction coefficients at the interface between the tube and die on the loading path and thickness distribution of the formed product are discussed. Experiments of protrusion hydroforming are also conducted. The final shape and thickness distribution of the formed product are compared with the simulation results to verify the validity of this modeling.

Sign in / Sign up

Export Citation Format

Share Document