Loading Path Optimization of T-shape Tube Hydroforming Process

2004

An approach is presented to optimize a tube hydroforming process using a Genetic Algorithm (GA) search method. The goal of the study is to maximize formability by identifying the optimal internal hydraulic pressure and feed rate while satisfying the forming limit diagram (FLD). The optimization software HEEDS is used in combination with the nonlinear structural finite element code LS-DYNA to carry out the investigation. In particular, a sub-region of a circular tube blank is formed into a square die. Compared to the best results of a manual optimization procedure, a 55% increase in expansion was achieved when using the pressure and feed profiles identified by the automated optimization procedure.

International Journal of Material Forming, 2008

For three dimensional tube hydroforming operations (i.e. T or Y shaped tubes) the calibration of both material feeding history and internal pressure path during the process is crucial and many approaches to such optimization were presented; the authors developed some procedures to optimize pressure paths and punch velocity histories with the application of an integrated method FEM - Gradient based optimization tools. In this paper, an experimental validation campaign of the utilized optimization strategies is presented with the aim to assess the effectiveness of the developed procedures. An optimization procedure (gradient based techniques) was applied on the process parameters leading to the determination of an optimal pressure path. Finally, a testing machine was set up to carry out hydroforming operations on T-shaped tubes. The developed equipment allows a computer assisted control of both the internal fluid pressure paths and the punches actions (material feeding paths). The experimental evidences validated the results obtained by the optimization strategies utilized to design the process parameters.

2012

Tube hydroforming is mostly applied in automotive industry. In this respect, necessity for the procedure improvement of flu id forming is constant. One of the reasons of its improvement is the procedure performance in optimal conditions. The process parameters have the direct in fluen ce on quality and optimal of forming procedure. This paper provides an example of the fluid p ressure optimization in T-shape tube hydroforming. Three types of material have been analysed, with three wall thickness and three course levels of axial printers. For the optimizat ion, the evolutional method with applied genetic algorith m (GA) was utilized. The applicat ion of GA is significant in solving of many problems in engineering practice. The simp licity and adaptability of the genetic algorithm to the engine ering problem results with the increasing volume of applications in a research work. In this paper we investigated interactions of the internal parameters of the T tube hydroforming process, towards achieving the GA model fo r the optimal internal pressure, necessary for hydroforming.

2009

The Tube Hydroforming Process (THF) is a relatively complex manufacturing process; the performance of this process depends on various parameters like internal pressure, axial loading etc. and requires proper combination of part design, material selection and boundary conditions. Due to the complex nature of the process, the behaviour of this processes are studied experimentally. Current study involves experimental work on tube hydroforming. Study on various parameters of the tube hydroforming process to approach optimum process parameters. How different materials and process parameters influence the loading paths. The study was a part of a large investigation.

The tube hydro forming process (THF) is an unconventional metal forming process, where in tube is deformed internally and thus it is forced to expand and conform to the shape of the surrounding die. The performance of this process depends on various parameters like internal pressure, axial loading etc. For FEA simulation, it requires proper combination of material selection, part design and boundary conditions. The estimated process parameters are optimized using FEA simulations. In this work, free bulge shaped tube die was modeled by using Auto CAD. Subsequently, the processes were simulated using DEFORM-3D and it has been verified with experimental work under proper boundary and loading condition. Process parameters study also been conducted. It has been found that the estimated process parameters, developed branch height and the wall thickness distribution along different planes are in good coincidence with experimental results.

SN Applied Sciences, 2021

The objective of this study is to improve the bulging and minimize the thinning ratio to enhance manufacturing of components in Industries. Tube hydroforming is an advanced manufacturing technology used for making intricate and complex tubular parts which required less cycle time. This research focuses on hydroforming process, formability and process parameters design to replace the conventional tube bending, welding and cutting operations. The prediction of parameters is done by applying numerical and experimental approach. During experimentation the pressurized fluid is used to deform the tubes in a plastic deformation. In this study, two types of grade materials are used such as AISI304 and AISI409L of 57.15 mm external diameter with 1.5 mm thickness in the form of electric resistance welded tubes to measure stain path, thinning and bulge height. However, it is observed that the internal pressure and L/D ratio are effective parameters in both numerical analysis and experimentatio...

2010

The success in tube hydroforming (THF) technology depends on an appropriate loading path w hich could be described as the combination between the a xial force or the axial punch displacement and the inter nal pressure. In the paper is presented a numerical stu dy about the tube hydroforming process of a profilated part, considering as the main parameters the presence or the absence of the axial displacement of the punches an d different friction coefficients. Using finite element method it has been demonstrated that the combination of th e tube hydroforming process parameters could be determined very efficiently. The simulated results recommend t he deformation with axial moving of the punches as the best method to control the part quality and to generate successful part without fracture or wrinkling failu re.

Materials Today: Proceedings, 2018

Tube hydroforming (THF) is an essential manufacturing technique in the modern days and in general, THF has become a convenient method for built-up complex automobile parts. This process depends mainly on the process parameters like internal pressure, axial feeds, material properties, and other processing conditions. Design by simulation has usually been a trial and error process, where the purpose is to find a feasible and cost effective process to produce a defect free product by altering process parameters. In this study tools required for the tube hydroforming process has modeled in the cad package CATIA V5 and these are imported into the commercial finite element code PAM-STAMP 2G for conducting the simulations. The effects of different process parameters have been investigated by numerical analysis and also the Taguchi Technique for optimization on Aluminum alloy Al99. The optimum conditions have been determined based on their effect on bulge height and thinning distribution of the tube material. Three important process parameters i.e., Internal Pressure, Axial feed and Frictional Coefficient were investigated. Finally, the mutual effect on Aforesaid process parameters on bulge height and thinning distribution were studied.

The shaping by hydroforming process involves several complex phenomena and presents several types of nonlinearities (geometric, material, etc.). The development of a hydroforming operation requires a lot of testing to determine with precision the optimum loads of trips and get a room without defects. Advances in digital tools have enabled manufacturers to simulate and optimize their production facilities before launching the production in order to minimize the maximum rate of defective parts. Several techniques or deterministic optimization methods have been proposed over the last decade in order to properly conduct a formatting operation. The majority of these techniques combine the finite element method and optimization techniques.

Journal of Materials Processing Technology, 2003

In this paper, effect of loading path and variation in material properties on the robustness of the tube hydroforming process and ®nal part requirements (i.e. thickness speci®cations) were studied experimentally and computationally. Small and simple tube hydroforming parts were used in the FE analysis to obtain some guidelines on the use of different loading path schemes. Developed guidelines, then, were applied experimentally on a production scale automotive structural frame part. Results emphasized the importance of the loading path design once more whereas variation of mechanical properties of incoming tubing within the experimented range was not found to be signi®cantly effective on the ®nal part speci®cations.