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On process parameter estimation for the tube hydroforming process
Linköpings universitet, Institutionen för ekonomisk och industriell utveckling, Hållfasthetslära. Linköpings universitet, Tekniska högskolan.
Linköpings universitet, Institutionen för ekonomisk och industriell utveckling, Hållfasthetslära. Linköpings universitet, Tekniska högskolan.
Linköpings universitet, Institutionen för ekonomisk och industriell utveckling, Hållfasthetslära. Linköpings universitet, Tekniska högskolan.
2007 (Engelska)Ingår i: Journal of Materials Processing Technology, ISSN 0924-0136, E-ISSN 1873-4774, Vol. 190, nr 1-3, s. 1-11Artikel i tidskrift (Refereegranskat) Published
Abstract [en]

Tube hydroforming is a forming process where an inner pressure combined with axial feeding deforms the tube to the shape of a die cavity. One of the main concerns when designing such a process is to avoid burst pressure, i.e. the process state where the hardening of the material is unable to resist the increase in inner pressure and wall thickness reduction. The success of a hydroforming process strongly depends on the choice of process parameters, i.e. the combination of material feeding and inner pressure. Especially in hydroforming processes, where the free forming phase is substantial, the process is proved to be very sensitive to the inner pressure. By transforming the problem into a deformation controlled rather than a force controlled process, the results from the process parameter estimation become more reliable but on the other hand less intuitive. In this context, three distinct parameter estimation procedures are suggested. Firstly, a self feeding based procedure is proposed with the intention of being a fast method to be used as a first estimate of suitable process parameters. Secondly, an iterative optimization problem set up is presented. Thirdly, and finally, an adaptive simulation procedure based on process response approximations is proposed, which only requires a limited number of simulation runs.

Ort, förlag, år, upplaga, sidor
2007. Vol. 190, nr 1-3, s. 1-11
Nyckelord [en]
Aluminium alloys, Hydroforming, Adaptive process, Optimization
Nationell ämneskategori
Teknik och teknologier
Identifikatorer
URN: urn:nbn:se:liu:diva-14249DOI: 10.1016/j.jmatprotec.2007.02.050OAI: oai:DiVA.org:liu-14249DiVA, id: diva2:23010
Tillgänglig från: 2007-01-25 Skapad: 2007-01-25 Senast uppdaterad: 2017-12-13
Ingår i avhandling
1. Hydro-mechanical forming of aluminium tubes: on constitutive modelling and process design
Öppna denna publikation i ny flik eller fönster >>Hydro-mechanical forming of aluminium tubes: on constitutive modelling and process design
2006 (Engelska)Doktorsavhandling, sammanläggning (Övrigt vetenskapligt)
Abstract [en]

Tube hydroforming is a forming method which has several advantages. By using pressure in combination with material feeding it is possible to manufacture products with high structural integration and tight dimensional tolerances. The forming method is especially suited for aluminium alloys which have a relatively low ductility. Finite Element simulations are used extensively in the sheet metal stamping industry, where the methodology has contributed to a better understanding of the process and the new prediction capability has significantly reduced costly die tryouts. Similarly, the tube hydroforming industry can benefit from Finite Element simulations, and this simulation methodology is the topic of this dissertation.

Deep drawing and tube hydroforming have a basic difference, namely that the latter process essentially is a force controlled process. This fact, in combination with the anisotropic behaviour of aluminium tubes, enforces a need for accurate constitutive descriptions. Furthermore, the material testing needs to account for the specifics of tube hydroforming. The importance of proper material modelling is in this work shown for hydrobulging and hydroforming in a die with extensive feeding.

The process parameters in hydroforming are the inner pressure and the material feeding, where a correct combination of these parameters is crucial for the success of the process. It is here shown, that Finite Element simulations together with an optimisation routine are powerful tools for estimating the process parameters in an automated procedure.

Finally, the reliability and quality of the simulation results depend on how failure is evaluated, which in the case of hydroforming mainly oncerns wrinkling and strain localisation. Since tube hydroforming often is preceded by bending operations this fact also demands the criteria to be strain path independent. In this work, it is shown that the prediction of strain localisation depends on the ability to predict diffuse necking, which in turn is strongly related to the chosen constitutive model.

Ort, förlag, år, upplaga, sidor
Institutionen för konstruktions- och produktionsteknik, 2006
Serie
Linköping Studies in Science and Technology. Dissertations, ISSN 0345-7524 ; 1048
Nyckelord
Hydroforming, Aluminium Extrusions, Anisotropic material
Nationell ämneskategori
Teknisk mekanik
Identifikatorer
urn:nbn:se:liu:diva-8161 (URN)91-85643-78-5 (ISBN)
Disputation
2006-11-17, Planck, Hus E, Campus Valla, Linköpings universitet, Linköping, 00:00 (Engelska)
Opponent
Handledare
Tillgänglig från: 2007-01-25 Skapad: 2007-01-25 Senast uppdaterad: 2020-03-24

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Jansson, MikaelNilsson, LarsgunnarSimonsson, Kjell

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