Experimental and numerical analyses of sheet hydroforming process for production of an automobile body part (original) (raw)
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Experimental modeling of fluid pressure during hydroforming of welded plates
Advances in Production Engineering & Management, 2016
The procedure of hydroforming belongs to one of the modern methods of sheet and tube design, usually of complex configuration. Research in the field of plastic forming using fluids usually relates to the analysis of important parameters that would enable high-quality design of elements and execution of the process in stable conditions. The hydroforming process of welded sheets found its application in manufacturing of tanks and other sheet parts in automotive industry, where, in addition to technical and technological characteristics of the obtained piece, it is necessary to achieve stability of the process and its economic feasibility. Experimental research in this paper had been aimed at the analysis of results and modeling of working fluid pressure during hydroforming of welded sheets of two kinds of material (St 37 and Al 99.5) for two sheet thicknesses (1.5 mm and 2.0 mm). Modeling was done by regression method, whose analysis is the determination of functional relationships between a dependent variable and two independent variables. Application of mathematical modeling method enabled working fluid pressure which confirmed the impact of input variables of hydroforming process (yield strength and sheets thickness) onto the values of working fluid pressure. Experimental results obtained for working fluid pressure enabled easier planning and projection of hydroforming process.
An Experimental Study of the Sheet Hydroforming Process
Sixth International Conference on Advances in Civil Structural and Mechanical Engineering CSM 2018, 2018
Hydroforming of aluminum sheets is a plastic deformation process largely used in automotive industry. Among the different hydroforming processes, the Flexform is the one in which the punch is replaced by a fluid cell. This cell consists of a rubber membrane that is filled with a controlled pressure fluid that will deform the sheet in the tool. A rigid die is used for obtaining the shape of the workpiece. For obtaining a sound product a balance between the pressure fluid and the blank material and geometry must be assured. The paper presents experiments carried out for analyzing the influence of the die geometry, the blank thickness and the fluid pressure toward the product accuracy, in terms of thickness and shape variations. The results will be useful in process modeling and in estimation of hydro-deformability of aluminum sheets.
Automotive component development by means of hydroforming
Archives of Civil and Mechanical Engineering, 2008
Hydroforming processes have become popular in recent years, due to the increasing demands for lightweight parts in various fields, such as bicycle, automotive, aircraft and aerospace industries. This technology is relatively new as compared with rolling, forging or stamping, therefore there is not much knowledge available for the product or process designers. Comparing to conventional manufacturing via stamping and welding, tube (THF) and sheet (SHF) hydroforming offers several advantages, such as decrease in workpiece cost, tool cost and product weight, improvement of structural stability and increase of the strength and stiffness of the formed parts, more uniform thickness distribution, fewer secondary operations, etc. The paper presents extensive possibilities of component development in automotive industry by means of hydroforming processes. There are also presented some examples on computer modelling of these processes and limiting phenomena.
Feasibility Study of Complex Sheet Hydroforming Process: Experimental and Modelling
Key Engineering Materials
The application of finite element method (FEM) in the area of metal forming and material processing has significantly increased in the recent years. The presented study provides details of the development of a finite element modelling approach to form a part via sheet hydroforming (SHF) process. Both FEM analysis and experimental trials were introduced in this study to produce a complex shape component from Inconel 718 material. The FEM provides a robust feasibility study for forming this part in terms of blank design, load path and process design optimisation. The simulated hydroformed part was validated by performing experimental trials. The analysis demonstrated close correlation between the predicted FE model and the physical trial.
Predictions of formability parameters in tube hydroforming process
SN Applied Sciences, 2021
The objective of this study is to improve the bulging and minimize the thinning ratio to enhance manufacturing of components in Industries. Tube hydroforming is an advanced manufacturing technology used for making intricate and complex tubular parts which required less cycle time. This research focuses on hydroforming process, formability and process parameters design to replace the conventional tube bending, welding and cutting operations. The prediction of parameters is done by applying numerical and experimental approach. During experimentation the pressurized fluid is used to deform the tubes in a plastic deformation. In this study, two types of grade materials are used such as AISI304 and AISI409L of 57.15 mm external diameter with 1.5 mm thickness in the form of electric resistance welded tubes to measure stain path, thinning and bulge height. However, it is observed that the internal pressure and L/D ratio are effective parameters in both numerical analysis and experimentatio...
A Systematic Review of Sheet Metal Hydro Forming Process
Hydro forming technology is very useful for the light weight material include low carbon/mild steel for chassis and side rails, aluminium, and its alloy for automotive body, stainless steel for exhaust system part. There are many process Parameters like as hydraulic pressure, blank-holding force, die radius, material properties, and coefficient of friction affect thee sheet hydro forming process. Purposes of the study can be improve the competitiveness of sheet hydro forming by new setup to reduced various defects , increase the production rate of auto body parts at lower initial investment cost.
Journal of Materials Processing Technology, 2009
Hydroforming is one of the new technologies in the manufacturing processes, in which hollow pieces are formed under pressure of a fluid. The basic parameter in this process is the pressure control of the fluid. This article deals with the process of hydroforming of a pair of metal sheets. After obtaining the kinematically admissible velocity field, the pressure equation is obtained by the upper bound analysis. This equation can be applied for each part if the instantaneous geometry of the deformed sheet in the die cavity zone during the process can be analytically expressed. The effects of the parameters of work-hardening, friction and blank size have been taken into considerations. To validate the results of this work a hemispherical part formed in the hydroforming of single-sheet process has been considered. The results obtained by this analysis have been compared with the experimental results.
Analysis of key parameters in sheet hydroforming combined with stretching forming and deep drawing
Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2004
Sheet hydroforming has proven to be an effective method for manufacturing complicated parts. To explore sheet deformation under complex strain conditions, the forming process of a conical cup was studied on the basis of the proposed hydromechanical deep drawing with uniform pressure on to the blank. The failure types including fracture and wrinkling were analysed in detail. The process windows for the pressure in the die cavity were drawn out using the different roughness of the punch surface in local areas. The forming process of the conical cup was explored using pure aluminium and soft steel. Effects of the key process parameters including the punch surface roughness and the pressure variation on the finally formed parts were investigated in both experiment and simulation. It was shown that the results from the simulation were in reasonable agreement with those from the experiment.