the tube expansion, as shown in below Figure1.Ref [2], in 2002 have analyzed necking & bursting effect in flange & tube hydroforming by considering influence of material & process parameter. Which were applied to illustrating for tube and flange hydro-forming, …
Many experimental studies concerning bulge forming ... simulation of an axisymmetric tube bulging operation using ABAQUS software. To evaluate the influence of the new friction model, theoretical ...
1. Introduction. Hollow parts are commonly used to replace solid parts to reduce product weight and save material as well as to make full use of the material's strength [].The aluminum alloy tube is a common hollow part which can be formed into different types of irregular tubes; square section tubes are widely used in the aerospace and automobile industries [].
Electromagnetic forming (EMF) technology uses pulsed current to generate a pulsed electromagnetic force on metal workpiece to accomplish plastic deformation. It is a promising solution for the room temperature processing of lightweight alloy. Coil de
The effects of the forming rate on tube flowability at 250 ° C are also investigated. Through the observation of the flow line configurations of the tube material, adequate backward speeds of the counter punch relative to the axial feeding for preventing the material from accumulating at the die entrance region are verified.
bulging using LS-DYNA [5]. The processes of circular bulging and T-shape formation were simulated by Brewster, et al. [6] using Pam-Stamp. To reduce defects in THF, the applied internal pressure must be high enough to suppress buckling but low enough so as not to cause tube bursting. In conventional process simulation procedures, a
Figure 16 shows the comparison of the bulging height of composite tubes formed by experiment and simulation. Since the bulging height in this paper refers to the distance between the inner walls of the tube, when composite tubes were hydroformed, there is no space to measure the bulging height of the inner wall of the outer tube, therefore ...
Tube hydroforming is an attractive manufacturing process in the automotive industry because it has several advantages over alternative methods. In order to determine the reliability of the process, a new method to assess the probability of failure is proposed in this paper.
In this paper, we study the tube hydroforming process, under the combined action of an axial end feed and injected fluid pressure that plastically deform the tube and force it to conform to the shape of the die (Fig. 1). The challenge is to be able to perform the entire operation without a defect that can cause the rejection of the part.
Due to the fact that geometrical structure of tube electromagnetic bulging process with field shaper does not conform to the axisymmetric property, three-dimensional (3D) model is usually used to analyze the process which is complicated and time consuming. Therefore, on the basis of understanding the working principle of the field shaper, a two-dimensional (2D) model with current …
The hydraulic bulging technology of tubes can provide hollow parts with special-shaped cross sections. Its manufacturing process can effectively improve material utilization and product accuracy and reduce the number and cost of molds. However, the hydraulic bulging process of parts is very complicated. The size of the tube blank, the design of the loading route, and the forming process ...
2.3. Numerical simulation modelling plan of part forming process In order to study the results of different forming process, meanwhile, confirm the most suitable forming process for box shaped part, five simulation schemes were proposed as below: Table 1. Forming schemes of box shaped part Scheme number Preforming Final forming
To investigate the surface roughening behavior of 6063 aluminum alloy tube during hydroforming, bulging experiments were carried out using the hydroformability test setup shown in Figure 2 a. For this, tubes with a length–diameter ratio of 1.5 (i.e., a tube length of 112.5 mm) were fixed to a specially designed block, and then bulged using ...
A static friction model for tube bulge forming using a solid bulging medium. Download. A static friction model for tube bulge forming using a solid bulging medium. Zaidi Ripin. Related Papers. Computer aided modelling of friction in rubber-pad forming process. By Mohd Ripin and Roslan Ahmad.
Figure 1 (Left) An FEA model at intermediate stages of forming simulation of a uniform-thickness tube shows that the wall remains thick at the tube end but thins in the bulge area. The most dramatic thinning is at the bulge center. (Right) Measuring the tube's wall thickness along its length after bulging shows that the wall thinned from 2.30 mm to less than 1.85 mm at the bulge center.
12%Mg/Al bimetallic tubes can give full play to the excellent properties of magnesium alloys and aluminum alloys, such as light weight, high strength and good corrosion resistance. In this study, gas bulging forming and contradictive cooling bonding process was used to form AZ31/Al7475 hexagonal section composite tubes and showed a good result. In addition, the finite …
AbstractThis study investigated localized expansion in the tube hydroforming process, which may induce cracks in the tube material. First, a model …
Tube bulging test consists in deforming a tube plastically by applying an internal pressure. Strain takes place only on a short (but long enough compared to thickness) length of the tube. The unstrained parts are blocked by closing plungers. A CAD model of the experimental system is given in Fig. 1 a and b.
Bulging propagates completely under fixed initial coexistent voltage using air chamber volume the ratio of bulged section grows from 0 to 1 (a), the change of total charge (b) and the change of longitudinal and hoop stretches of the bulged and unbulged sections (c), some configurations of the tube during bulging propagation (d).
Abstract. This study is to propose a loading scheme combined with die crushing and axial feeding to manufacture a profiled tube with different end shapes. Carbon steel of SPFC590Y is used as the tube material. The flow stresses of SPFC590Y steel tube at room temperature are obtained by tensile tests. A finite element software DYNAFORM is ...
Bulge test simulation Figure 10 shows the proposed design of the device and its main features (die, blank holder, bolt holes, gasket groove, drawbead, and fluid inlet hole). The objective of this simulation is to verify that a stress of 700 MPa can be reached in the specimens with proposed parameters (p, D, t o, h).
to the complex nature of the process, the behaviour of the process will be done in the simulation study. The simulation model will be prepared and analyzed by FEM tool DEFORM-3D. The main object of the proposed study is to examine the influence of various factors like friction between the dies and tube blank, axial plunger feeding and internal ...
In this paper,the experimental study on the thermal bulging of AZ31 magnesium alloy sheet is carried out,including the thermal bulging test of magnetic pulse impact viscous medium and the thermal bulging test of quasi-static viscous medium.The effects of different discharge energies and different temperatures on the bulging of magnetic pulse ...
Study Case-1: Run the crash tube model as it is. This image shows the case-1 tube crash in which the model is running as it is. ... If such a divided lower part is big enough, al large bulge on each end of the part is formed. This bulge or bent metal is out of the line of force and doesn't undergo compression initially as the tube continues ...
Consequently, it is very meaningful to study the attraction bulging of a tube. Moreover, we have previously conducted a simulation study on this problem. The simulation results showed that the final deformation can be increased by increasing the slope at the falling edge or reducing the slope at the second rising edge of the discharge current.
Exp Mech In this study, a dynamic bulge testing technique is 48:293–306 simulated and analyzed to perform biaxial tests on metals 8. Meng H, Li QM (2003) Correlation between the accuracy of a at high strain rates. The main conclusions of this research SHPB test and the stress uniformity based on numerical experiments.
Tube bending is a widely used manufacturing process in the aerospace, automotive, and various other industries. During tube bending, considerable in-plane distortion and thickness variation occurs. Additional loadings such as axial force and internal pressure can …
The objective of the proposed study is to analyse, in the case of an electromagnetic bulging process for thin sheets, the influence of process parameters on the deformed blank geometry. The effects of charging voltage, coil geometry and capacitance of capacitor bank are therefore studied.
A series of tube bulge tests for tube hydroforming are simulated by a commercial finite element solver to predict the limit strains. Numerical simulation of forming limit strains in tube hydroforming with different internal pressure and different simulation set up with or without axial feeding are considered to develop wide range of strain ...
tube could withstand an internal pressure varying from 163.8% to 192.1% when compared with the aluminium tube. Finally, the increase of the number of bulges resulted in a small change varying from 0% to 3.1% when compared with the one bulge tube. Keywords: Bulge forming, tube-bulging, hydroforming, bellows, finite element (FE) analysis, simulation
