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Hydroforming of sheet metal

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lightbulbAbout this topic
Hydroforming of sheet metal is a manufacturing process that uses high-pressure hydraulic fluid to shape metal sheets into desired forms. This technique allows for the production of complex geometries with improved material properties and reduced waste, making it an efficient method for creating lightweight and structurally sound components in various industries.
lightbulbAbout this topic
Hydroforming of sheet metal is a manufacturing process that uses high-pressure hydraulic fluid to shape metal sheets into desired forms. This technique allows for the production of complex geometries with improved material properties and reduced waste, making it an efficient method for creating lightweight and structurally sound components in various industries.

Key research themes

1. How can adaptive and optimized pressure path control improve formability and reduce defects in sheet metal hydroforming?

This research area investigates the role of precise control and optimization of fluid and back pressures, as well as blank holder forces, in enhancing formability and minimizing instabilities such as wrinkling and tearing during sheet metal hydroforming. Adaptive numerical methods integrating finite element analysis with control algorithms are applied to optimize loading profiles dynamically according to material behavior and geometry, thereby enabling the processing of complex shapes with high accuracy and fewer defects.

Key finding: This study applied a novel integration of double-sided hydroforming process (DSHP) with adaptive finite element analysis and type-2 fuzzy logic control (T2FLC) along with genetic algorithms to optimize back pressure and... Read more
Key finding: Using a genetic algorithm combined with finite element modelling, this research identified optimum fluid pressure paths for producing complex two-stepped sheet metal parts in a single forming step. The optimization minimized... Read more
Key finding: Through a comprehensive experimental characterization, the authors established quantitative relationships between forming fluid pressure, blank holder force, and frictional conditions in sheet hydroforming with die (SHF-D).... Read more
Key finding: This paper presents an improved wrinkling prediction model that incorporates through-thickness normal stresses induced by fluid pressure in warm/hot sheet hydroforming, validated experimentally using an enhanced Yoshida... Read more

2. What modeling strategies effectively predict formability limits and strain localization in sheet metal hydroforming?

This theme focuses on theoretical and numerical models developed to predict the onset of localized necking, fracture, and forming limits in sheet hydroforming. Emphasis is given to constitutive models like the Marciniak-Kuczynski (M-K) model, forming limit diagrams (FLD), and coupled damage mechanics that incorporate microstructural and strain path effects. These models facilitate understanding material behavior under complex loading and improving the reliability of simulations used for process design and failure prevention.

Key finding: This review consolidates extensive developments of the M-K model for predicting sheet metal formability, highlighting its evolution from simple geometrical imperfection assumptions to sophisticated versions incorporating... Read more
by Xing ZHAO and 
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Key finding: The book provides foundational mechanics models for sheet metal forming, including hydroforming, establishing mechanics-based approaches that bridge the gap between elastic-plastic deformation theories and industrial forming... Read more
Key finding: This review critically examines factors influencing forming limit curves (FLC) in sheet metals, including measurement methods, strain paths, microstructure, strain rate, and temperature effects. It highlights the relevance of... Read more
Key finding: This study integrates numerical finite element analysis with experimental validation to predict formability parameters such as thinning, bulging height, and strain paths in tube hydroforming of stainless steel tubes. It... Read more

3. How do advanced high-speed forming and assisted forming techniques influence hydroforming effectiveness and material formability?

This research theme explores the adoption of novel forming strategies such as electromagnetic forming (EMF), electrohydraulic forming (EHF), heat-assisted forming, and double-sided hydroforming to overcome traditional limitations in hydroforming. These techniques aim to increase material ductility, reduce forming forces, improve strain rates, and expand formability windows for challenging materials like high-strength aluminum alloys and lightweight metals. Experimental and numerical investigations elucidate the underlying mechanisms and process optimization strategies.

Key finding: This paper compares electrohydraulic forming (EHF) and electromagnetic forming (EMF) as high-speed incremental sheet forming processes, analyzing electromagnetic and mechanical load transmission, deformation dynamics, and... Read more
Key finding: This research investigates hydroforming of 7xxx series high-strength aluminum tubes using thermo-mechanical approaches including W-temper and hot forming under quenching conditions. Tensile testing at elevated temperatures... Read more
Key finding: This review summarizes developments in heat-assisted incremental sheet forming (ISF), emphasizing strategies to improve formability of high-strength alloys such as titanium and steels through integrated heating sources... Read more
Key finding: Through coordinated experimental and simulation studies, this work quantifies strains in aluminum, copper, and steel sheets subjected to electromagnetic forming (EMF). The findings demonstrate significantly increased forming... Read more

All papers in Hydroforming of sheet metal

A challenge to conduct the most accurate FE simulations in Warm Hydromechanical Deep Drawing (WHDD) process is to predict temperature condition of the blank which was held between the heated dies and cooled punch. This is possible by... more
Hydro mechanical deep drawing (HDD) process is an advanced sheet metal forming technology. The aim of this process is to form deep drawn cups without any kind of forming instability such as buckling, wrinkling or bursting (tearing). The... more
Post-print of "SM Mirfalah-Nasiri, A Basti, R Hashemi (2016) Forming limit curves analysis of aluminum alloy considering the through-thickness normal stress, anisotropic yield functions and strain rate, Abstract Based on three anisotropic... more
Increasing use of hydroforming in automotive applications requires intensive research and development on all aspects of this relatively new technology to satisfy an ever-increasing demand by the industry. This paper summarizes a... more
The prediction of optimized forming parameters viz. the punch force, blank holding force, forming factor, and hydrostatic pressure will contribute to cost reduction of the processed metal through curtailment in material usage and... more
In this paper, the formability of two-layer (aluminum-st12 steel) sheets in the deep drawing process was investigated through numerical simulations and experiments. The purpose of this research was to obtain more formability in deep... more
Keywords: Forming limit diagram Strain path Punch geometry Microstructure Strain rate Temperature A B S T R A C T Sheet metal forming industry widely adopted the forming limit curve (FLC) as a limiting criterion in sheet metal forming.... more
The paper describes a new method for the identification of the flow stress curves of anisotropic sheet metals using a hydraulic bulge tests through circular and elliptical dies. This method is based on analytical model using the membrane... more
In this paper, an improved approach is proposed to determine the optimal profiles of two controllable process parameters (hydraulic pressure and blank holder force), which improve the forming condition and/or make better use of forming... more
Austenitic stainless steel sheets are important technological materials due to their diverse applications ranging from chemical transportation, shipbuilding, automotive and aircraft industry. During deformation at room temperature or at... more
Hydro mechanical deep drawing (HDD) process is an advanced sheet metal forming technology. The aim of this process is to form deep drawn cups without any kind of forming instability such as buckling, wrinkling or bursting (tearing). The... more
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... more
In this article, for the first time, the forming limit diagram (FLD) and mechanical properties of aluminum foil samples processed by the accumulative roll bonding (ARB) process have been studied experimentally. For this purpose, thin... more
Under the leadership of the Kyoto agreements on reducing emissions of greenhouse gases, the automotive sector was forced to review its methods and production technologies in order to meet the new environmental standards. In fuel... more
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