Research on flattening behavior of wrinkled 5A02 aluminum alloy tubes under internal pressure

Wang, Xiaosong; Cui, Xiao-Lei; Yuan, Shijian

doi:10.1007/s00170-016-8529-0

Cited by 4 publications

(4 citation statements)

References 17 publications

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“…The tube has an outer diameter of 63 mm with a nominal thickness of 2 mm. The material was taken out from the extruded tube and then annealed at 380 °C for about 2h [9,14,15]. Table 1 shows the mechanical properties of the material.…”

Section: Materials Modulementioning

confidence: 99%

“…In Stage 2, the grooved tubes were blown up to take the final shape of the die. This model has also been validated using published experimental results [9,15]. Table 2 and Table 3 compare simulation results to experimental results.…”

Section: Interactions and Boundary Conditionsmentioning

confidence: 99%

“…Generic THF has the same material module, interactions, and loading path as grooved THF. The FE Model results were validated against the experimental results published in the literature [9,15]. This work was expanded with a change in the pressure loading path, as shown in Figs.…”

Section: Interactions and Boundary Conditionsmentioning

confidence: 99%

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Numerical Investigation on Influence of Grooves on Tube Hydroforming Process of Aluminium Alloys

Ramanathan,

Ramesh,

Achuthankutty

2024

Period. Polytech. Mech. Eng.

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For several decades, scientists and engineers have been using the tube hydroforming (THF) process for numerous applications in the automotive and aerospace industries. The inert advantages like weight reduction without compromising on strength, improved part quality, better surface finish, and reduced tooling costs have motivated the use of THF in the fabrication industry. The presence of grooves on the pre-forms was found to immensely help in increasing the pressure-withstanding capacity of the THF tubes, in addition to reducing the stress concentration and achieving the near-net shape during the THF process. This project involves the development of a detailed Finite Element Model, for the THF process. Numerical analysis is carried out in two stages: Stage-1: Groove Formation, and Stage-2: Final THF tube formation. In Stage 1, the numerical model investigates the formation of grooves, predicting the amount of internal pressure and axial feeding that are required to accurately form them. In Stage 2, numerical simulations focus on the actual THF process. This two-stage THF process (Grooved-THF) was compared to a single-stage Generic THF process. The results indicate the Grooved-THF to be producing a relatively lower thickness reduction with a more closely formed corner radius compared to the generic case. The work also involves multi-objective optimization of the process parameters like the number of grooves, coefficient of friction, internal fluid pressure, and die corner radius using the DOE technique – RSM. The results indicate the number of grooves and the friction coefficient to be the most influencing parameters in the THF process.

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Section: Materials Modulementioning

confidence: 99%

Section: Interactions and Boundary Conditionsmentioning

confidence: 99%

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Numerical Investigation on Influence of Grooves on Tube Hydroforming Process of Aluminium Alloys

Ramanathan,

Ramesh,

Achuthankutty

2024

Period. Polytech. Mech. Eng.

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“…On the basis of it, the useful wrinkles have been proposed and applied to enlarge the process window [14]. It has been demonstrated that useful wrinkles can improve the forming limit and thickness distribution by increasing axial feeding [15,16]. Wrinkling defects, however, may occur easily due to the axial feeding if the diameter-to-thickness ratio (D/t) of the part is extremely large [17].…”

Section: Samples and Materialsmentioning

confidence: 99%

Circumferential Material Flow in the Hydroforming of Overlapping Blanks

Han

Feng

2020

Metals

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The hydroforming of the overlapping blanks is a forming process where overlapping tubular blanks are used instead of tubes to enhance the forming limit and improve the thickness distribution. A distinguishing characteristic of the hydroforming of overlapping blanks is that the material can flow along the circumferential direction easily. In this research, the circumferential material flow was investigated using overlapping blanks with axial constraints to study the circumferential material flow in the hydroforming of a variable-diameter part. AISI 304 stainless steel blanks were selected for numerical simulation and experimental research. The circumferential material flow distribution was obtained from the profile at the edge of the overlap. The peak value located at the middle cross-section. In addition, the circumferential material flow could be also reflected in the variation of the overlap angle. The variation of the overlap angle kept increasing as the initial overlap angle increased but the improvement of the thickness distribution did not. There was an optimal initial overlap angle to minimize the thinning ratio. An optimal thickness distribution was obtained when the initial angle was 120° for the hydroforming of the variable-diameter part with an expansion of 31.6%.

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Effects of mechanical property parameters on wrinkling behavior of thin-walled tubes in hydroforming process

Cui

Wang

Yuan

2018

Int J Adv Manuf Technol

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Research on flattening behavior of wrinkled 5A02 aluminum alloy tubes under internal pressure

Cited by 4 publications

References 17 publications

Numerical Investigation on Influence of Grooves on Tube Hydroforming Process of Aluminium Alloys

Numerical Investigation on Influence of Grooves on Tube Hydroforming Process of Aluminium Alloys

Circumferential Material Flow in the Hydroforming of Overlapping Blanks

Effects of mechanical property parameters on wrinkling behavior of thin-walled tubes in hydroforming process

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