Experimental investigation of friction coefficient in tube hydroforming

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.

Classification and Analysis of Tube Hydroforming Processes with Respect to Adaptive FEM Simulations

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.

Analysis of the Internal Pressure in Tube Hydroforming and Its Experimental Investigation

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.

State of the Art and Perspectives of Hydroforming of Tubes and Sheets

Hollow parts of high accuracy and high strength can be produced by forming methods using liquid media. Hydroforming of tubes has reached a high standard for small parts (volume some 1000 cm3) and is further developed for larger parts (volume some 10.000 cm3). Processes for hydraulic sheet metal forming are sometimes used for small parts from single sheets These pro-cesses are currently under intensive investigation, which is also true for the processing of double layered sheets Single sheets can be formed using membranes which separate the workpiece and the liquid. This results in interesting possibilities for a part and process integration in one step The forming performance of aluminum alloys can be enhanced by using a heated liquid media when forming without membranes.

Optimizing loading path and die linetype of large length-to-diameter ratio metal stator screw lining hydroforming

In order to meet the high temperature environment requirement of deep and superdeep well exploitation, a technology of large length-to-diameter ratio metal stator screw lining meshing with rotor is presented. Based on the elastic-plasticity theory, and under the consideration of the effect of tube size, material mechanical parameters, friction coefficient and loading paths, the external pressure plastic forming mechanical model of metal stator screw lining is established, to study the optimal loading path of metal stator lining tube hydroforming process. The results show that wall thickness reduction of the external pressure tube hydroforming(THF) is about 4%, and three evaluation criteria of metal stator screw lining forming quality are presented: fillet stick mold coefficient, thickness relative error and forming quality coefficient. The smaller the three criteria are, the better the forming quality is.Each indicator has a trend of increase with the loading rate reducing, and the adjustment laws of die arc transition zone equidistance profile curve are acquired for improving tube forming quality. Hence, the research results prove the feasibility of external pressure THF used for processing high-accuracy large length-to-diameter ratio metal stator screw lining, and provide theoretical basis for designing new kind of stator structure which has better performance and longer service life.

Experimental and Numerical Research on Deformation Behavior of Thin-Walled and Large Expansion Ratio Guide Vane Liner in Hydroforming Process

Some tube hydroforming process tests and further research work were conducted to manufacture hollow guide vane liners( made of super alloy GH3030).The relative thickness( t0/ OD) of the tubular blank is approximately 0. 01,and the maximum expansion ratio( Dmax/ OD) of the needed part is more than 40%,and the length to diameter ratio of the expansion regionis more than 3. 0. It is very hard to manufacture this kind of ultra-thin-wall,curved axis and large expansion ratio tubular part without fracture and wrinkles. The success of the process is highly dependent on useful wrinkles with appropriate internal pressure and axial feeding. A simplified finite element model and a theoretical model are used for detecting the deformation behavior and forming laws. Further study results demonstrate that the useful wrinkles do not appear at the same time and middle-wrinkles need bigger axial force than tube-end-wrinkles and feeding-wrinkles. The wrinkles can transfer bigger axial force after its wave peak has come into contact with the die inner surface. The thickness thinning rate of the element at the peak is bigger than that at the trough. With the increase of the axial and hoop stress ratio,the critical buckling stress also increases. Microstructure examination results show that the grain size in the maximum thinning zone has been stretched and refined after the large deformation and annealing treatment.The process is feasible and the finished part is qualified.

OPTIMIZATION OF SHEET METAL FORMING PROCESSES USING FINITE ELEMENT SIMULATIONS

The paper focuses on the combination of the Finite Element simulation and optimization to improve process or product quality. Three different examples to illustrate the developed genetic approach are given. In all three examples is-DYNA3D is used to simulate the process and a general aptimiza- tion sensitivity based strategy is utilized to improve the design. The included examples are: 1) stretch bending of tubes, 2) bulging of tubes, and finally 3) hydromechanical deep drawing. these examples clearly illustrate the potential of systematic optimization in the area of metal processing.