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On constitutive modeling of aluminum alloys for tube hydroforming applications
Linköping University, Department of Management and Engineering, Solid Mechanics . Linköping University, The Institute of Technology.
Linköping University, Department of Management and Engineering, Solid Mechanics . Linköping University, The Institute of Technology.
Linköping University, Department of Management and Engineering, Solid Mechanics . Linköping University, The Institute of Technology.
2005 (English)In: International Journal of Plasticity, ISSN 0749-6419, Vol. 21, no 5, 1041-1058 p.Article in journal (Refereed) Published
Abstract [en]

The increased interest in lightweight materials for automotive structures has also lead to a search for efficient forming methods that suit these materials. One attractive concept is to use hydroforming of aluminum tubes. The advantages of this forming method includes better tolerances, decreased number of parts and an increased range of forming options. By using FE simulations, the process can be optimized to reduce the risk for failure, i.e. bursting or wrinkling. However, extruded aluminum is highly anisotropic and it is crucial that the material model used for simulations is able to accurately describe this behavior. Also, tube hydroforming occurs predominantly in a biaxial stress state which should be considered in the material testing, where uniaxial tests are used extensively in the industry today. The present study accentuates the need for improved constitutive models. It is shown that a material model, which accurately describes the anisotropic behavior of aluminum tubes, can be obtained from simple and robust experiments.

Place, publisher, year, edition, pages
2005. Vol. 21, no 5, 1041-1058 p.
Keyword [en]
Aluminum alloys; Hydroforming; Anisotropic material; Biaxial loading
National Category
Engineering and Technology
Identifiers
URN: urn:nbn:se:liu:diva-14246DOI: 10.1016/j.ijplas.2004.06.005OAI: oai:DiVA.org:liu-14246DiVA: diva2:23007
Available from: 2007-01-25 Created: 2007-01-25
In thesis
1. Hydro-mechanical forming of aluminium tubes: on constitutive modelling and process design
Open this publication in new window or tab >>Hydro-mechanical forming of aluminium tubes: on constitutive modelling and process design
2006 (English)Doctoral thesis, comprehensive summary (Other academic)
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.

Place, publisher, year, edition, pages
Institutionen för konstruktions- och produktionsteknik, 2006
Series
Linköping Studies in Science and Technology. Dissertations, ISSN 0345-7524 ; 1048
Keyword
Hydroforming, Aluminium Extrusions, Anisotropic material
National Category
Applied Mechanics
Identifiers
urn:nbn:se:liu:diva-8161 (URN)91-85643-78-5 (ISBN)
Public defence
2006-11-17, Planck, Hus E, Campus Valla, Linköpings universitet, Linköping, 00:00 (English)
Opponent
Supervisors
Available from: 2007-01-25 Created: 2007-01-25 Last updated: 2009-02-26

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Jansson, MikaelNilsson, LarsgunnarSimonsson, Kjell

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