Experimental Study of Ultrasonic Vibration Effects on Punch Radial in Sheet Hydroforming Process

Ghasemi, Reza Hasanzadeh; Elyasi, Majid; Baseri, Hamid; Mirnia, Mohammad Javad

doi:10.21203/rs.3.rs-1121252/v1

“…Previously, some researchers have used ultrasonic vibrations in some metal forming processes. As an example, one can mention applying vibrations to the sheet holder, mandrel and die in the process of deep drawing [17][18][19], sheet hydroforming [20] wire drawing [21,22], tensile testing, [23] upsetting [24,25], direct extrusion [26], micro-extrusion [27,28], and incremental forming [29,30].…”

Section: Introductionmentioning

confidence: 99%

Numerical and experimental investigation of the ultrasonic vibration effects on the tube hydroforming process in a die with a square cross-section

Shahri

¹

,

Lakhi

²

,

Taheridoustabad

³

2023

Int J Adv Manuf Technol

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The use of tube hydroforming process to produce integrated parts is growing in various industries. In this research, the hydroforming process has been used to convert the circular cross-section of the tube into a square one. In this process, due to the high hydrostatic pressure of the fluid, the friction in the contact area between the tube and the die surface increases significantly. High friction prevents the metal flowing of the tube material on the die surface and therefore it becomes very difficult to completely form the tube inside the die and obtain sharp corners. In this research, in order to improve the tube formability, applying ultrasonic vibrations to the hydroforming die has been used, which causes a temporary gap to be created in the contact surface of the tube and the die, and therefore the amount of friction is reduced and the tube material can slide more easily. By developing a 3D finite element model, the ultrasonic tube hydroforming process was evaluated. Modal analysis was used to evaluate the different shape modes of the die. The effects of ultrasonic vibrations on the deformation process have been evaluated using two variables: corner radius of square die and average wall thickness. An ultrasonic hydroforming setup was designed to form the annealed copper tube and was stimulated using selected resonance frequencies. The results of the finite element model were validated with the deformed tube in the experimental test. After confirming the results, the numerical model was used to evaluate the process parameters.

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A review of emerging hydroforming technologies: design considerations, parametric studies, and recent innovations

Chinchanikar,

Mulik,

Varude

et al. 2024

J. Eng. Appl. Sci.

0

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Hydroforming is a modern metal-forming process prominently used in the shipbuilding, aerospace, and automotive industries for forming lightweight, complex-shaped geometries due to their inherent process benefits. But this process faces challenges such as limited material selection, high tooling costs, and complex process control for obtaining a defect-free part with uniform thickness. Researchers are constantly innovating and advancing hydroforming technologies to overcome these limitations. This work reviews emerging tube and sheet hydroforming technologies, considering parametric effects and design considerations, particularly for micro-domain applications. Further, a wider acceptance of the hydroforming process in different industries is explored by discussing the studies that tried to improve the efficiency and quality of the hydroforming process. This study observed that better formability could be achieved in hydroforming with appropriate intermediate heat treatment, proper lubrication, the correct design of loading paths, and temperature distribution. In tube hydroforming, wrinkles, necking, and cracking observed to be largely reduced by properly selecting the internal pressure and feeding. The precise protrusion height and uniform thickness at different joint cross-sections in tube forming are found to be significantly influenced by the strain-hardening exponent, loading path, and friction coefficient. Electrohydraulic forming is found being increasingly used due to its higher productivity and lower product cost. However, further research is required to achieve complex sheet geometries with sharp corners. This research emphasizes that advanced research, artificial intelligence integration, and the exploration of alternative materials can improve the performance of the hydroforming process.

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Numerical and experimental investigation of the ultrasonic vibrations effects on the tube hydroforming process in a die with a square cross-section

Shahri¹,

Lakhi²,

Doostabad³

2022

Preprint

0

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The use of tube hydroforming process to produce integrated parts is growing in various industries. In this research, the hydroforming process has been used to convert the circular cross-section of the tube into a square one. In this process, due to the high hydrostatic pressure of the fluid, the friction in the contact area between the tube and the die surface increases significantly. High friction prevents the metal flowing of the tube material on the die surface and therefore it becomes very difficult to completely form the tube inside the die and obtain sharp corners. In this research, in order to improve the tube formability, applying ultrasonic vibrations to the hydroforming die has been used, which causes a temporary gap to be created in the contact surface of the tube and the die, and therefore the amount of friction is reduced and the tube material can slide more easily. By developing a 3D finite element model, the ultrasonic tube hydroforming process was evaluated. Modal analysis was used to evaluate the different shape modes of the die. The effects of ultrasonic vibrations on the deformation process have been evaluated using two variables: corner radius of square die and average wall thickness. An ultrasonic hydroforming setup was designed to form the annealed copper tube and was stimulated using selected resonance frequencies. The results of the finite element model were validated with the deformed tube in the experimental test. After confirming the results, the numerical model was used to evaluate the process parameters.

show abstract

Experimental Study of Ultrasonic Vibration Effects on Punch Radial in Sheet Hydroforming Process

Cited by 3 publications

References 10 publications

Numerical and experimental investigation of the ultrasonic vibration effects on the tube hydroforming process in a die with a square cross-section

Numerical and experimental investigation of the ultrasonic vibration effects on the tube hydroforming process in a die with a square cross-section

A review of emerging hydroforming technologies: design considerations, parametric studies, and recent innovations

Numerical and experimental investigation of the ultrasonic vibrations effects on the tube hydroforming process in a die with a square cross-section

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