Tube hydroforming—research and practical application

Dohmann, F.; Hartl, C.

doi:10.1016/s0924-0136(97)00166-0

Cited by 203 publications

(106 citation statements)

References 3 publications

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“…Tube hydroforming has been successfully developed in industry such as in the manufacturing of the components of automotive vehicles [3]. In fact tube hydroforming is called as a soft-punch forming technology [4]. Steel tube has excellent strength to weight ratio and therefore its applications can effectively reduce vehicle weight and improve vehicle stiffness.…”

Section: Introductionmentioning

confidence: 99%

Pressurization System in Low Pressure Tube Hydroforming

Nikhare¹

2013

MNSMS

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Advanced high strength steels are the group of material with high strength and good formability, because high strength lesser gauge thickness can be used without compromising the function of component. In terms of economic forming process, hydroforming is the manufacturing option which uses a fluid medium to form a component by using high internal pressure. This process gained steep interest in the automotive and aerospace industries because of its many advantages such as part consolidation, good quality of the formed part etc. The main advantage is that the uniform pressure can be transferred to whole projected part at the same time. Low pressure tube hydroforming considered an inexpensive option for forming these advanced high strength steel. This paper investigates the pressurization system used during the low pressure tube hydroforming cycle. It is observed that the usage of ramp pressure cycle during forming the part from low pressure tube hydroforming results in lesser die holding force. Also, the stress, strain and thickness distribution of the part during low pressure tube hydroforming are critically analysed.

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Section: Introductionmentioning

confidence: 99%

Pressurization System in Low Pressure Tube Hydroforming

Nikhare¹

2013

MNSMS

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“…Due to the increasing demands for the manufacturing of complex and lightweight parts in various fields, the hydroforming process of welded tubes (WT), considered as an alternative to stamping for obtaining the hollow tubular structures, occupies an increasingly significant place in automotive aircraft and aerospace industries [1][2][3]. a However, the effective use of the hydroforming technology in the manufacturing industry has triggered new challenges in terms of the technological parameters specified for the forming process and particularly the material properties of the WT [4][5].…”

Section: Introductionmentioning

confidence: 99%

Optimization technics to identify the characteristics of a hydroformed structure

Radi

Cherouat

Hami

et al. 2010

Int. J. Simul. Multidisci. Des. Optim.

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-This paper presents an experimental/numerical methodology which aims to improve 3D welded tube considering their anisotropic effect, geometrical singularities found in the welded joint, and heat affected zone behaviour by hydroforming process. This process contributes to reduce the number of welding and assembly operations needed to generate complex structures, while improving the weight saving and quality of finished parts. In spite of the advances in the performance of this manufacturing technology, some problems are linked to particularities of certain raw materials and additional studies must be developed, like in the case of welded tubes. The experimental study is dedicated to the identification of stress-strain flow of the base metal and the heat-affected zone from the global measure of tube displacement, thickness evolution and internal pressure expansion. Nanoindentation test is adapted to investigate the heat affected zone mechanical behaviour. Workpiece behaviour's models used to simulate the expansion tests, made it possible to highlight the combined effects of the inhomogeneous behaviour of basic material and heat affected zone, as well as the geometrical singularities found in the welded tubes. From the simulations carried out, it is clear the influence of the plastic flow behaviour of the welded tube in the final results (thickness distribution, stress instability, tube circularity, critical thinning and rupture).

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“…Recently, this technology has been gaining increasing attention and applications can now be found in the automobile and the aircraft industries. [1][2][3][4] Notwithstanding, there are still difficult problems to which conventional technical know-how cannot be applied, such as designing the loading paths of hydraulic pressure and the amount of axial feeding. The capability of the hydroforming process is also largely governed by the outcome of the pre-forming processes.…”

Section: Introductionmentioning

confidence: 99%

“…[4][5][6][7][8][9][10][11][12][13][14] Through these studies, process characteristics of tube hydroforming have been gradually understood. On the other hand, there are only a few reports on the forming ability of actual engineering parts, from either an experimental or a theoretical point of view.…”

Section: Introductionmentioning

confidence: 99%

Simulation of Hammering Hydroforming by Static Explicit FEM

et al. 2004

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Recently, tube hydroforming is receiving increasing attention. Knowledge on the process is, however, still insufficient to produce high-quality products in an efficient way. Hammering hydroforming, in which the hydraulic pressure is pulsated synchronously with axial feeding, is an effective method of improving forming ability. However, the factors that cause the improvement are still unclear. In the research reported in this paper, simulations of an automotive component produced by hammering hydroforming have been performed using a static explicit finite-element method code, which was developed in this study. The simulation results showed a good agreement with the experiment, thus validating the hammering hydroforming simulation by the developed code. The factors that improve the forming ability were also investigated by simulation. It was clarified that the hammering forming has the advantage of obtaining enough expansion as well as the regular forming with the lower friction force by using the lower pressure history. Moreover, that roughly the same effect as lowering the friction coefficient could be achieved by the hammering hydroforming.KEY WORDS: tube hydroforming; hammering forming; static explicit finite-element method; strain path, displacement in the longitudinal direction.tions. 23) An updated Lagrangian rate formulation is used to describe the finite deformation. The rate form of the equilibrium equations and boundary conditions are equivalently expressed by the principle of virtual velocity in the form 24) ..................... (1) where V and S denote, respectively, the domain occupied by the body and its boundary at time t. s is the Cauchy stress tensor, t J is the Jaumann rate of the Kirchhoff stress tensor, L is the velocity gradient tensor, and D is the strain rate tensor, which is the symmetric part of L. dv is the virtual velocity field satisfying the condition dvϭ0 on the velocity boundary. S G is the part of the boundary S on which the rate of hydraulic pressure p is prescribed. S C is the part of the boundary S on which the rate of traction f (other than the hydraulic pressure) is prescribed.As for constitutive equations, small strain linear elasticity and large deformation rate-independent work-hardening plasticity are assumed. Hill's quadratic yield function 25) and the associated flow rule are used. The equation can be written in the formijkl are the tangent elastoplastic moduli. The solution procedure for the formulation stated above follows the standard way of static explicit analysis using the r-minimum strategy. 26) Simulation Model Suspension ComponentIn this study, the forming processes of a suspension component of an automobile shown in Fig. 1(a) 2) were simulated. This component is formed through multistage processes: the pre-bending process, the die-closing process, and the hydroforming process. During the hydroforming process, pressure up to 140 MPa and axial feeding up to 200 mm are applied. Ultimately, 43 % of maximum expansion is achieved.In the actual industrial production...

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Tube hydroforming—research and practical application

Cited by 203 publications

References 3 publications

Pressurization System in Low Pressure Tube Hydroforming

Pressurization System in Low Pressure Tube Hydroforming

Optimization technics to identify the characteristics of a hydroformed structure

Simulation of Hammering Hydroforming by Static Explicit FEM

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