Investigation of the Effect of Loading Paths in the Tube Hydroforming Process

2018 ◽  
Vol 18 (2) ◽  
pp. 40-52
Author(s):  
Adil Shbeeb Jaber
Keyword(s):  
Tube Hydroforming ◽  
Loading Paths ◽  
Hydroforming Process

The effect of tube dimensions on optimized pressure and force loading paths in tube hydroforming process

2012 ◽  
Vol 26 (6) ◽  
pp. 1817-1822 ◽  
Author(s):  
S. M. H. Seyedkashi ◽  
H. Moslemi Naeini ◽  
G. H. Liaghat ◽  
M. Mosavi Mashadi ◽  
M. Mirzaali ◽  
...  
Keyword(s):  
Tube Hydroforming ◽  
Force Loading ◽  
Loading Paths ◽  
Hydroforming Process

Real-Time Friction Error Compensation in Tube Hydroforming Process Control

2011 ◽  
Vol 133 (6) ◽  
Author(s):  
Gracious Ngaile ◽  
Chen Yang ◽  
Obadiah Kilonzo
Keyword(s):  
Process Control ◽  
Real Time ◽  
Error Compensation ◽  
Tube Hydroforming ◽  
Loading Path ◽  
Forming Process ◽  
Loading Paths ◽  
Proposed Model ◽  
Metal Forming Process ◽  
Hydroforming Process

Tube hydroforming (THF) is a metal-forming process that uses a pressurized fluid in place of a hard tool to plastically deform a given tube into a desired shape. In addition to the internal pressure, the tube material is fed axially toward the die cavity. One of the challenges in THF is the nonlinear and varying friction conditions at the tube-tool interface, which make it difficult to establish accurate loading paths (pressure versus feed) for THF. A THF process control model that can compensate for the loading path deviation due to frictional errors in tube hydroforming is proposed. In the proposed model, an algorithm and a software platform have been developed such that the sensed forming load from a THF machine is mapped to a database containing a set of loading paths that correspond to different friction conditions for a specific part. A real-time friction error compensation is then carried out by readjusting the loading path as the THF process progresses. This scheme reduces part failures that would normally occur due to variability in friction conditions. The implementation and experimental verification of the proposed model is discussed.

Real Time Friction Error Compensation in Tube Hydroforming Process Control

2011 ◽  
Author(s):  
Gracious Ngaile ◽  
Obadiah Kilonzo ◽  
Chen Yang
Keyword(s):  
Process Control ◽  
Real Time ◽  
Error Compensation ◽  
Tube Hydroforming ◽  
Loading Path ◽  
Forming Process ◽  
Loading Paths ◽  
Proposed Model ◽  
Metal Forming Process ◽  
Hydroforming Process

Tube Hydroforming (THF) is a metal-forming process that uses a pressurized fluid in place of a hard tool to plastically deform a given tube into a desired shape. In addition to the internal pressure, the tube material is fed axially toward the die cavity. One of the challenges in THF is the nonlinear and varying friction conditions at the tube-tool interface, which make it difficult to establish accurate loading paths (pressure vs feed) for THF. A THF process control model that can compensate for the loading path deviation due to frictional errors in tube hydroforming is proposed. In the proposed model, an algorithm and a software platform have been developed such that the sensed forming load from a THF machine is mapped to a database containing a set of loading paths that correspond to different friction conditions for a specific part. A real-time friction error compensation is then carried out by readjusting the loading path as the THF process progresses. This scheme reduces part failures that would normally occur due to variability in friction conditions. The implementation and experimental verification of the proposed model is discussed.

T-Shape Tube Hydroforming of Magnesium Alloys With Different Outlet Diameters

2011 ◽  
Vol 133 (6) ◽  
Author(s):  
Yeong-Maw Hwang ◽  
Kuo-Hsing Wang ◽  
Nai-Shin Kang
Keyword(s):  
Flow Pattern ◽  
Magnesium Alloys ◽  
Flow Line ◽  
Tube Hydroforming ◽  
Speed Ratio ◽  
Design Guideline ◽  
Loading Paths ◽  
Die Surface ◽  
Hydroforming Process ◽  
Warm Hydroforming

Good die surface shapes improve the flow pattern of the tube material, reduce stress concentration of the products, and decrease the forming load. The objective of this paper is to propose a design guideline for die surface shapes in T-shape protrusion hydroforming of magnesium alloys with different outlet diameters and propose an adaptive control algorithm to determine appropriate loading paths for the forming process. The finite element analysis is used to simulate the flow pattern of the tube during tube hydroforming process. The analytical flow line distribution of the tube is utilized to determine the speed ratio of the counter punch to the axial feeding at the protrusion stage of the hydroforming process. Experiments of T-shape warm hydroforming of magnesium alloy AZ61 tubes with a 1/2 outlet diameter ratio are conducted. Loading paths determined by the proposed adaptive simulation algorithm is adopted in the tube hydroforming (THF) experiments. From the comparisons of the product shape, thickness distribution, and flow line configuration between the analytical and experimental values, the validity of the proposed die design guidelines and control algorithms is verified.

Optimization of Tube Hydroforming Process Using Probabilistic Constraints on Failure Modes

2011 ◽  
Vol 62 ◽  
pp. 21-35 ◽  
Author(s):  
Anis Ben Abdessalem ◽  
A. El Hami
Keyword(s):  
Failure Modes ◽  
High Reliability ◽  
Thickness Distribution ◽  
Tube Hydroforming ◽  
Forming Limit Diagram ◽  
Plastic Instability ◽  
Probabilistic Constraints ◽  
Forming Limit ◽  
Reliability Based Design ◽  
Hydroforming Process

In metal forming processes, different parameters (Material constants, geometric dimensions, loads …) exhibits unavoidable scatter that lead the process unreliable and unstable. In this paper, we interest particularly in tube hydroforming process (THP). This process consists to apply an inner pressure combined to an axial displacement to manufacture the part. During the manufacturing phase, inappropriate choice of the loading paths can lead to failure. Deterministic approaches are unable to optimize the process with taking into account to the uncertainty. In this work, we introduce the Reliability-Based Design Optimization (RBDO) to optimize the process under probabilistic considerations to ensure a high reliability level and stability during the manufacturing phase and avoid the occurrence of such plastic instability. Taking account of the uncertainty offer to the process a high stability associated with a low probability of failure. The definition of the objective function and the probabilistic constraints takes advantages from the Forming Limit Diagram (FLD) and the Forming Limit Stress Diagram (FLSD) used as a failure criterion to detect the occurrence of wrinkling, severe thinning, and necking. A THP is then introduced as an example to illustrate the proposed approach. The results show the robustness and efficiency of RBDO to improve thickness distribution and minimize the risk of potential failure modes.

Optimization for Loading Paths of Tube Hydroforming Using a Hybrid Method

2009 ◽  
Vol 24 (6) ◽  
pp. 700-708 ◽  
Author(s):  
Zhang Yong ◽  
Luen Chow Chan ◽  
Wang Chunguang ◽  
Wu Pei
Keyword(s):  
Hybrid Method ◽  
Tube Hydroforming ◽  
Loading Paths

scholarly journals Numerical investigation of plastic flow and residual stresses generated in hydroformed tubes

2021 ◽  
pp. 146442072198974
Author(s):  
A Ktari ◽  
A Abdelkefi ◽  
N Guermazi ◽  
P Malecot ◽  
N Boudeau
Keyword(s):  
Finite Element ◽  
Residual Stresses ◽  
Finite Element Model ◽  
Plastic Flow ◽  
Tube Hydroforming ◽  
Three Dimensional ◽  
Element Model ◽  
Tube Cross Section ◽  
Straight Wall ◽  
Hydroforming Process

During tube hydroforming process, the friction conditions between the tube and the die have a great importance on the material plastic flow and the distribution of residual stresses of the final component. Indeed, a three-dimensional finite element model of a tube hydroforming process in the case of square section die has been performed, using dynamic and static approaches, to study the effect of the friction conditions on both plastic flow and residual stresses induced by the process. First, a comparative study between numerical and experimental results has been carried out to validate the finite element model. After that, various coefficients of friction were considered to study their effect on the thinning phenomenon and the residual stresses distribution. Different points have been retained from this study. The thinning is located in the transition zone cited between the straight wall and the corner zones of hydroformed tube due to the die–tube contact conditions changes during the process. In addition, it is clear that both die–tube friction conditions and the tube bending effects, which occurs respectively in the tube straight wall and corner zones, are the principal causes of the obtained residual stresses distribution along the tube cross-section.

Experimental Researches upon Changes of a Pipe's Roughness after Hydroformation

2013 ◽  
Vol 371 ◽  
pp. 111-115
Author(s):  
Bogdan Constantin Vaceanu ◽  
Gheorghe Nagit ◽  
Vasile Huian
Keyword(s):  
Surface Roughness ◽  
Tube Hydroforming ◽  
Work Piece ◽  
Copper Pipe ◽  
Work Area ◽  
The Coefficient Of Friction ◽  
Hydroforming Process ◽  
Aluminum Pipe ◽  
Experimental Researches

Surface roughness was studied in the tube hydroforming process, considering the quality of the material and the coefficient of friction between the work piece and die. Other researchers have studied the surface roughness to the front of an aluminum pipe [. The aim of this work was to analyze changes in a copper pipe roughness occurred after hydroforming process with fluid. Effects of changing roughness were studied, following the deformation of the material in the work area and roughness changes occurring in the material flow. After achieving hydroforming process, the surface roughness was measured by electron microscopy SEM in different areas of the hydro formed tube. After hydroforming process, an increase of surface roughness in connection areas of the mold to the curvature and the transverse direction of the pipe.

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