Latest Hydroforming Technology of Metallic Tubes and Sheets

Hwang, Yeong‐Maw; Manabe, Ken‐ichi

doi:10.3390/met11091360

Cited by 24 publications

(8 citation statements)

References 16 publications

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“…, 2023; Marlapalle and Hingole, 2021; Bell et al. , 2020; Hwang and Manabe, 2021). At present, there is ongoing research on single-layer multi-pass tubes, such as T-shaped, X-shaped and Y-shaped tubes.…”

Section: Introductionmentioning

confidence: 99%

“…It is a simple and environmentally friendly production process that produces high-quality components. This technology is capable of producing complex pipe fittings while reducing the manufacturing cycle, resulting in cost reduction and achieving lightweight designs (Mohseni et al, 2023;Marlapalle and Hingole, 2021;Bell et al, 2020;Hwang and Manabe, 2021). At present, there is ongoing research on single-layer multi-pass tubes, such as T-shaped, X-shaped and Y-shaped tubes.…”

Section: Introductionmentioning

confidence: 99%

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Hydroforming of double-layer Y-shaped tube controlled by a novel backward punch shape

Feng,

Jia,

Sun

et al. 2023

IJSI

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PurposeA new backward punch shape was designed and used in the hydroforming process of double-layer Y-shaped tubes to achieve uniform wall thickness. This study focuses on the implementation and effectiveness of this novel punch shape.Design/methodology/approachA numerical simulation and experimental validation of the hydroforming process of double-layer Y-shaped tubes under various backward punch, replenishment ratios (left and right feed ratios) and internal pressure loading paths was performed using finite elements. During the hydroforming process, an analysis was made on the distribution of stress, strain and wall thickness in both the inner and outer layers of the Y-shaped conduit.FindingsThe novel backward punch parallel to the main tube has been found to improve the distribution of wall thickness in Y-shaped tubes. By controlling the feeding ratio and modifying the loading path of the internal pressure, it is possible to obtain the optimal forming part of the double-layer Y-shaped tube. The comparison between the simulation and experimental results of the double-layer Y-shaped tube formed under the optimal path indicates that the error is within 5% and the distribution of wall thickness is consistent.Originality/valueA novel backward punch technique is employed to control the hydroforming process in a Y-shaped tube. A study on hydroforming of double-layer Y-shaped tubes with asymmetric features and challenging forming conditions is being suggested.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Hydroforming of double-layer Y-shaped tube controlled by a novel backward punch shape

Feng,

Jia,

Sun

et al. 2023

IJSI

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“…Researchers also determined the buckling characteristics of dieless hydroformed egg-shaped shell preforms 15 using theoretical and numerical analysis and came to the conclusion that the developed shells can withstand sufficient external pressure. A review article on latest hydroforming techniques for tubes and sheets has been recently published by Hwang and Manabe 16 where the authors explained three techniques namely tube hydroforming (THF), tube forming and sheet hydroforming (SHF) in detail. Another recent article published by Morishima and Manabe 17 demonstrated a novel warm tube hydroforming (WTHF) process for magnesium alloy and determined the optimum wall thickness distribution using finite element analysis and experimental validation.…”

Section: Introductionmentioning

confidence: 99%

Evaluation of dieless hydroforming process for manufacturing of variable cross section tubular structures

Chandrasekar

Mukherjee

Singh

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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The dieless hydroforming is a type of manufacturing method that forms materials using pressurised hydraulic fluid rather than dies and presses as in traditional hydroforming, resulting in significant cost savings. The dieless hydroforming of tubular structures with variable cross section has received little attention, indicating that more research is needed in this area. Therefore, this article investigated dieless hydroforming of low carbon steel material with fluid pressures ranging from 10 to 50 bar and sheet thicknesses ranging from 1 to 2.5 mm to produce tubular structures with variable cross section. The main goal is to comprehend the deformation characteristics in relation to the parameters, as well as the impact of deformation on the microstructural and mechanical behaviour. The inflation and contraction patterns of hydroformed structures are numerically determined using the finite element method at various parameters and then compared to experimental results which show a good correlation. Plastic deformation induced grain refinement in all deformed samples, as compared to as-received material. The sample hydroformed at 30 bar and with a thickness of 2.5 mm showed higher yield strength (291 MPa), tensile strength (404 MPa) and elongation (48%) than the other samples. Hydroformed tubular structures with variable cross section are created and used in electric poles to hold solar panels after the process repeatability is tested and found to be highly repeatable with greater than 97% accuracy.

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“…Another area of application is the preliminary design of tube hydroforming processes. Recent reviews on this technology are provided in [18,19]. Despite the wide use of numerical methods for hydroforming process designs [20,21], simple semi-analytic solutions are essential for estimating the optimal values of the process parameters [22,23].…”

Section: Introductionmentioning

confidence: 99%

“…Substituting this equation into Equation (19), then, the resulting equation into Equation ( 7) and using Equation ( 5) yields…”

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confidence: 99%

An Analytic Solution for an Expanding/Contracting Strain-Hardening Viscoplastic Hollow Cylinder at Large Strains and Its Application to Tube Hydroforming Design

2021

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This paper presents a semi-analytic rigid/plastic solution for the expansion/contraction of a hollow cylinder at large strains. The constitutive equations comprise the yield criterion and its associated flow rule. The yield criterion is pressure-independent. The yield stress depends on the equivalent strain rate and the equivalent strain. No restriction is imposed on this dependence. The solution is facilitated using the equivalent strain rate as an independent variable instead of the polar radius. As a result, it reduces to ordinary integrals. In the course of deriving the solution above, the transformation between Eulerian and Lagrangian coordinates is used. A numerical example illustrates the solution for a material model available in the literature. A practical aspect of the solution is that it readily applies to the preliminary design of tube hydroforming processes.

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Latest Hydroforming Technology of Metallic Tubes and Sheets

Abstract: Hydroforming processes of metal tubes and sheets are being widely applied in manufacturing because of the increasing demand for lightweight parts in sectors such as the automobile, aerospace, and ship-building industries [...]

Cited by 24 publications

References 16 publications

Hydroforming of double-layer Y-shaped tube controlled by a novel backward punch shape

Hydroforming of double-layer Y-shaped tube controlled by a novel backward punch shape

Evaluation of dieless hydroforming process for manufacturing of variable cross section tubular structures

An Analytic Solution for an Expanding/Contracting Strain-Hardening Viscoplastic Hollow Cylinder at Large Strains and Its Application to Tube Hydroforming Design

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