Reshaping End-of-Life components by sheet hydroforming: An experimental and numerical analysis

Piccininni, Antonio; Cusanno, A.; Palumbo, G.; Zaheer, Omer; Ingarao, Giuseppe; Fratini, Livan

doi:10.1016/j.jmatprotec.2022.117650

Cited by 20 publications

(10 citation statements)

References 22 publications

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“…Combining Eqs. ( 15), (17), and ( 18), the non-uniform pressure caused by the material flow behavior is…”

Section: R a S A H A H S Z A H A S A H Smentioning

confidence: 99%

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Mechanism and experimental verification of non-uniform pressure in viscous pressure forming

Wang,

2024

Preprint

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The plastic deformation of the complex thin-walled components is not uniform. Applying a non-uniform load can decrease the thickness reduction and improve the thickness uniformity. In recent years, the application of non-uniform pressure to deform the sheet (such as magnetorheological pressure forming and viscous pressure forming) has attracted researchers’ attention. However, the characteristics of the non-uniform pressure have not been researched. Control of the non-uniform pressure in the forming process lacks theoretical support. In this study, the mechanism of the non-uniform pressure in the viscous pressure bulge test is investigated. The pressure-carrying medium, called viscous medium, is semi-solid and flowable. The inhomogeneous flow behavior of the medium produces non-uniform pressure when the maximum is at the bulged pole. The inhomogeneous deformation behavior of the medium produces non-uniform pressure when the minimum is at the bulged pole. The effects of flow and deformation are opposite. The non-uniform pressure function is derived, and the evolution of the pressure is presented. During forming, the viscosity of the medium increases with the pressure, so the effect of the flow behavior increases, and the pressure weight at the pole increases. Viscous pressure bulge tests are carried out to verify the theory. The gradient and evolution of the pressure can be controlled by the loading velocity and the property of the medium. The results provide theoretical guidance for the control of the pressure in viscous pressure forming, and the methodology is expected to analyze the non-uniform pressure in other flexible die forming processes.

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“…Combining Eqs. ( 15), (17), and ( 18), the non-uniform pressure caused by the material flow behavior is…”

Section: R a S A H A H S Z A H A S A H Smentioning

confidence: 99%

“…Plenty of components are deformed by flexible dies, such as water, oil, air, and rubber pads [15][16][17][18]. The flexible-die forming technology has many advantages, such as the simple die structure, the good filling capability, and the high quality of sheet surface [19,20].…”

Section: Introductionmentioning

confidence: 99%

Mechanism and experimental verification of non-uniform pressure in viscous pressure forming

Wang,

2024

Preprint

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“…Fig. 19 The pressure gradients of the required pressure to obtain the minimum polar strain at different polar heights…”

Section: Required Pressure To Obtain the Minimum Polar Strainmentioning

confidence: 99%

“…In these technologies, the pressure-carrying medium (fluid or air) is used to apply uniform pressure over the sheet, enabling the sheet to be deformed to complex shapes [19]. The application of flexible dies has many advantages, such as the simple die structure, the good filling capability, and the high quality of sheet surface [21][22].…”

Section: Introductionmentioning

confidence: 99%

Effect of the non-uniform pressure on the deformation and instability of the sheet in flexible-die bulge forming

Wang,

Wang

2024

Preprint

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In recent years, the application of non-uniform pressure in flexible-die forming, such as viscous pressure forming and magnetorheological pressure forming, has been utilized in manufacturing many thin-walled components. However, the non-uniform pressure is mainly applied to change the shape of the sheet. The effects of the non-uniform pressure on thickness reduction and fracture are still intricate. In this study, the mechanism of the non-uniform pressure to decrease thickness reduction and delay fracture instability in the bulge test is revealed. The non-uniform pressure changes the principal stresses, causing distinct deformation behaviors. There are two opposite effects on thickness reduction and fracture instability. If the pressure at the bulged pole decreases, the shape is more prolate, leading toa decreased average thickness and a decreased polar curvature. The thickness reduction tends to be severe, and the diffuse necking is easy to produce. If the pressure at the bulged pole increases, the shape is more oblate, leading to an increased strain gradient. The thickness reduction tends to be severe, and the localized necking is easy to produce. Characteristics of the pressure to decrease thickness reduction and delay instability are presented. Viscous pressure bulge tests are carried out. Experiment results of the shape, thickness uniformity, polar strain, and fracture verify the theory. The fracture strain increases by 5.6 % compared with the uniform pressure condition. This study proves that non-uniform pressure can promote sheet formability, indicating that non-uniform pressure has broad application prospects in sheet metal forming.

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“…Over recent years, the sheet hydroforming process has been extensively employed in various industrial sectors, such as automotive and aerospace, due to its noteworthy advantages in uniform thickness distribution, low springback, and higherdimensional accuracy compared to the conventional deep drawing process. [1][2][3] In sheet hydroforming, the use of a pressure medium facilitates the material flow during the process, leading to a better thickness distribution. [4,5] In other words, the pressurized fluid (usually water or oil) causes the sheet to adhere to the surface of the punch and deforms to its shape, [6,7] improving the geometrical accuracy of the formed part.…”

Section: Introductionmentioning

confidence: 99%

On Improving Sheet Metal Formability in Hydrodynamic Deep Drawing Process through a Solid‐Oil‐Type Mineral Grease Pressure Medium

Modanloo,

Akhoundi,

Lee

et al. 2023

steel research int.

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In this research, the improvement in sheet metal formability obtained through the utilization of a mineral grease in solid oil type (SMG) pressure medium in the hydrodynamic deep drawing process assisted by radial pressure (HDDRP) was investigated by experiments and finite element method (FEM) simulations on flat‐bottom cups realized with pure copper and DIN 1.0338 steel. To determine the process parameters ranges, a FEM model was developed in ABAQUS/Explicit and validated against experimental results. Afterward, experiments were carried out using two pressure mediums with different viscosities, id est water, and SMG. Considering the results relevant for both sheet materials, the SMG medium allowed an average reduction of the sheet metal thinning of 15% and 10% on the corner edges while also granting a negligible thickness variation on the cup walls. On the other hand, the higher viscosity of the SMG, in comparison to the water medium, also resulted in an average 16% increase in the forming force when compared to the water pressure medium.This article is protected by copyright. All rights reserved.

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Reshaping End-of-Life components by sheet hydroforming: An experimental and numerical analysis

Cited by 20 publications

References 22 publications

Mechanism and experimental verification of non-uniform pressure in viscous pressure forming

Mechanism and experimental verification of non-uniform pressure in viscous pressure forming

Effect of the non-uniform pressure on the deformation and instability of the sheet in flexible-die bulge forming

On Improving Sheet Metal Formability in Hydrodynamic Deep Drawing Process through a Solid‐Oil‐Type Mineral Grease Pressure Medium

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