Effect of the lubrication between the tube and the die on the corner filling when hydroforming of different cross-sectional shapes

Abdelkefi, Abderrahman; Guermazi, Noamen; Boudeau, Nathalie; Malécot, Pierrick; Haddar, Nader

doi:10.1007/s00170-016-8552-1

Cited by 22 publications

(3 citation statements)

References 27 publications

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“…The collected data were analyzed with an original program to determine the thickness repartition along the profile with a repeatability of ±1 µm. 19 For more details about the experimental procedure, see Abdelkefi et al. 19…”

Section: Materials and Techniquesmentioning

confidence: 99%

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Numerical investigation of plastic flow and residual stresses generated in hydroformed tubes

Ktari

Abdelkefi

Guermazi

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part L:

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During tube hydroforming process, the friction conditions between the tube and the die have a great importance on the material plastic flow and the distribution of residual stresses of the final component. Indeed, a three-dimensional finite element model of a tube hydroforming process in the case of square section die has been performed, using dynamic and static approaches, to study the effect of the friction conditions on both plastic flow and residual stresses induced by the process. First, a comparative study between numerical and experimental results has been carried out to validate the finite element model. After that, various coefficients of friction were considered to study their effect on the thinning phenomenon and the residual stresses distribution. Different points have been retained from this study. The thinning is located in the transition zone cited between the straight wall and the corner zones of hydroformed tube due to the die–tube contact conditions changes during the process. In addition, it is clear that both die–tube friction conditions and the tube bending effects, which occurs respectively in the tube straight wall and corner zones, are the principal causes of the obtained residual stresses distribution along the tube cross-section.

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Section: Materials and Techniquesmentioning

confidence: 99%

“…In the present work, the studied workpiece is an extruded tube made of deoxidized copper (Cu-DHP), 19 and manufactured by Wieland Group according to the NF EN 1057 standard. According to the specification, the outside mean diameter of the tube is 35 mm and the average thickness is 0.9 mm.…”

Section: Studied Materialsmentioning

confidence: 99%

Numerical investigation of plastic flow and residual stresses generated in hydroformed tubes

Ktari

Abdelkefi

Guermazi

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part L:

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show abstract

“…Abir Abdelkefi et al compared the wall thickness distribution of hydroformed square, rectangular, trapezoidal parts with or without lubricant. Regardless of the shape formed, the lubricant can greatly improve the uniformity of the wall thickness [10][11][12]. Secondly, the "beneficial wrinkles" is a subversive process method.…”

Section: Introductionmentioning

confidence: 99%

Thickness Improvement and Calibration Pressure Reduction of Stepped Tubular Components Using Axial Hydro-pressing Method

Han

Zhuang

2021

Preprint

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A new tube axial hydro-pressing method was proposed to solve the problems of high forming pressure and severely uneven wall thickness distribution of traditional tube hydroforming methods to form stepped tubular components. The forming pressure of the traditional hydroforming and the tube axial hydro-pressing method is studied theoretically, the mechanical model of the fillet area is established, and the forming pressure calculation formula is given. Based on this, an investigation of the tube axial hydro-pressing method is carried out by numerical simulation and experimental methods, and compared with the traditional tube hydroforming method. The key to the tube axial hydro-pressing method is to precisely control the relationship between the protrusion height and the axial feed, which is achieved by precisely controlling the feeding pressure and the axial displacement. Therefore, the constant pressure device in the experiment was used to eliminate the influence of the pressure rise caused by the volume compression on its cooperation relationship, to achieve accurate control of the loading path, eliminate wrinkles and flash defects. A qualified workpiece is successfully manufactured when the internal pressure is 18.0 MPa and the feed on each side is 15.0 mm. The forming pressure is reduced by 88.0%, and the feed is increased by 6.5%, which reduces the wall thickness reduction by 9.0%. The wall thickness difference of the workpiece can be controlled within 7.0%. The tube axial hydro-pressing method is suitable for forming stepped tubular components, which can achieve more replenishment at lower pressures, thereby effectively improving the uniformity of wall thickness and significantly reducing the forming pressure.

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Effect of Friction on Corner Filling Deformation in Tube Hydroforming Process by Real-Time Measurement

Cui,

Sun,

Yuan

2023

Lecture Notes in Mechanical Engineering

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Effect of the lubrication between the tube and the die on the corner filling when hydroforming of different cross-sectional shapes

Cited by 22 publications

References 27 publications

Numerical investigation of plastic flow and residual stresses generated in hydroformed tubes

Numerical investigation of plastic flow and residual stresses generated in hydroformed tubes

Thickness Improvement and Calibration Pressure Reduction of Stepped Tubular Components Using Axial Hydro-pressing Method

Effect of Friction on Corner Filling Deformation in Tube Hydroforming Process by Real-Time Measurement

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