Investigation of Effect of Process Parameters on Protrusion Height of Branched Parts in Tube Hydroforming

Document Type : Original Article

Authors

1 Assistant Professor, Department of Mechanical Engineering, Technical and Vocational University (TVU), Tehran, Iran

2 Assistant Professor, Department of Mechanical Engineering, Kar Higher Education Institute, Qazvin, Iran

Abstract

In tube hydroforming, by applying internal pressure using a fluid such as water or oil, bulging is created in the tube and the tube conforms to the inner walls of the die. In this paper, using hydroforming process in manufacturing of a branched joint with two branches on copper tubes has been investigated. This type of joint is used in various fluid transmission lines. Simulation of the forming process has been done in Abaqus finite element software. The effect of four important process parameters on the quality of the formed product has been studied. Considering the complex shape of the desired product, effect of four parameters of initial feeding, final feeding, yielding pressure and bursting pressure have been investigated and the effect of these parameters on the height of the formed branches and the maximum thinning has been determined. The results showed that with the appropriate selection of process parameters, a product with two branches with good quality can be obtained in one forming step. The most effective parameter on the height of the formed branch is the final feeding, so that increasing final feeding leads to more height of formed branches. On the other hand, bursting pressure has the most important parameter affecting the thinning. The initial feeding has the least effect on the thinning and the height of the formed branch.

Keywords

References

[1]  Dohmann F, Hartl C. Tube hydroforming—research and practical application. Journal of Materials Processing Technology: 1997; 71(1): 174-186. doi: 10.1016/S0924-0136(97)00166-0
[2]  Korkolis I. Formability and hydroforming of anisotropic aluminum tubes [dissertation]. University of Texas. 2009.
[3]  Lang L, Wang Z, Kang D, Yuan S, Zhang S-H, Danckert J. Hydroforming highlights: sheet hydroforming and tube hydroforming. Journal of Materials Processing Technology: 2004; 151 (1-3): 165-77. doi: 10.1016/j.jmatprotec.2004.04.032
[4]  Ahmetoglu M, Sutter K, Li X, Altan T. Tube hydroforming: current research, applications and need for training. Journal of Materials Processing Technology: 2000; 98 (2): 224-31. doi: 10.1016/S0924-0136(99)00203-4
[5]  Ahmetoglu M, Altan T. Tube hydroforming: state-of-the-art and future trends. Journal of Materials Processing Technology: 2000; 98 (1): 25-33. doi: 10.1016/S0924-0136(99)00302-7
[6]  Faupel J H. Yield and bursting characteristics of heavy wall cylinders. Transactions of the American Society of Mechanical Engineers: 1956; 78(5):1031-1064. doi: 10.1115/1.4013916
[7]  Dietmann H. The flow behavior of thick-walled cylinders under internal pressure, Bander Blech Rohre. 1967; 8 (3): 143-149. [In German]
[8]  Fuchs F J. Hydrostatic pressure its role in metal forming. Mechanical Engineering: 1966; 88(4), pp. 34-40.
[9]  Al-Qureshi H A. Comparison between the bulging of thin-walled tubes using rubber forming technique and hydraulic forming process. Sheet Metal Industries: 1970; 47: 607-612.
[10] Sauer W J. Gotera A, Robb F, Huang P. Free bulge forming of tubes under internal pressure and axial compression. in: Proceedings of the Sixth NAMRC: 1978: 228-235.
[11] Fuchizawa S. Infuence of strain hardening exponent on the deformation of thin-walled tube of finite length subjected to hydrostatic external pressure. Advanced Technology of Plasticity: 1984; 1: 297-302.
[12] Hashimi M S J, Crampton R. Hydraulic bulge forming of axisymmetric and asymmetric components: comparison of experimental results and theoretical predictions. in: Proceedings of the International MTDR Conference: 1985: 541-549.
[13] Asnafi N. Analytical modelling of tube hydroforming. Thin-Walled Structures: 1999; 34: 295–330. doi: 10.1016/S0263-8231(99)00018-X
[14] Seyedkashi S M H, Moslemi N H, Liaghat Gh, Mosavi M M, Shojaee K, Mirzaali M, Moon Y H. Experimental and numerical investigation of an adaptive simulated annealing technique in optimization of warm tube hydroforming. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture: 2012; 226(11): 1869-1879. doi: 10.1177/0954405412459611
[15] Hashemi R, Assempour A, Abad E M K. Implementation of the forming limit stress diagram to obtain suitable load path in tube hydroforming considering M–K model. Materials & Design: 2009; 30:3545-53.
[16] Liewald M. Magnesium Tube Hydroforming. 10th ESAFORM Conference on Material Forming. Zaragoza, Spain2007.
[17] Liewald M. Magnesium tube hydroforming. Materialwissenschaft und Werkstofftechnik: Entwicklung: 2008; 39:4-5. doi: 10.1002/mawe.200800303
[18] He Z-b, Liu G, Wu J, Yuan S-j, Liang Y-c. Mechanical property and formability of AZ31B extruded tube at elevated temperature. Transactions of Nonferrous Metals Society of China: 2008;18: 209-213. doi: 10.1016/S1003-6326(10)60204-X
[19] He Z, Yuan S, Liu G, Wu J, Cha W. Formability testing of AZ31B magnesium alloy tube at elevated temperature. Journal of Materials Processing Technology: 2010; 210: 877-884.
[20] Lin Y-l, He Z-b, Yuan S-j, Wu J. Formability determination of AZ31B tube for IHPF process at elevated temperature. Transactions of Nonferrous Metals Society of China: 2011; 21: 851-856. doi: 10.1016/S1003-6326(11)60792-9
[21] Kadkhodayan M, Moghadam A E. Optimization of load paths in X-and Y-shaped hydroforming. International Journal of Material Forming: 2013; 6: 75-91. doi: 10.1007/s12289-011-1074-3
[22] Liu G, Peng J, Yuan S, Teng B, Li K. Analysis on critical conditions of sidewall wrinkling for hydroforming of thin-walled Tee-joint. International Journal of Machine Tools and Manufacture: 2015; 97: 42-49. doi: 10.1016/j.ijmachtools.2015.06.004
[23] Cui X L, Yuan S. Analysis of thickness variation and stress state in hydroforming of complex T-shaped tubular part of nickel-based superalloy. Archives of Civil and Mechanical Engineering: 2021; 21: 1-14. doi: 10.1007/s43452-021-00263-x
[24] Chen M, Xiao X, Tong J, Guo H, Wen J. Optimization of loading path in hydroforming of parallel double branched tube through response surface methodology. Advances in Engineering Software: 2018; 115: 429-438. doi: 10.1016/j.advengsoft.2017.11.003
Iranian Journal of Manufacturing Engineering
Volume 10, Issue 1 - Serial Number 63
Best Paper of ICME 2022
March 2023
Pages 38-48

Files

Share

How to cite

Statistics