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THEORETICAL AND EXPERIMENTAL STUDY OF CONICAL TUBE HYDROFORMING WITH ONE-SIDED AXIAL FEEDING
Authors:
Yusra Jasim1
, Ghazwan Alwan1
, Tahseen Othman1
1Mechanical Engineering Department, Faculty of Engineering, Tikrit University, Iraq
Received: 12.06.2022.
Accepted: 26.09.2022.
Available: 30.09.2022.
Abstract:
Hydroforming has gained increasing attention in the manufacturing industry in recent years due to the demand for fast yet reliable production for parts, the applications of which accept a wide range of dimensional tolerances. In this study, tube hydroforming in conical dies has been analyzed. The study consists of two parts: computer simulations and experimental work. The simulation results were utilized to find the load paths which produce successful hydroforming for the selected tube specimens. Twelve load paths were identified and implemented with two friction coefficients and three pressure ranges. During the simulation process, the tubes were given an end movement that ranged from a sealing distance to twice that distance. The experimental work was implemented to verify some of the simulation results. The results showed that the best hydroforming limit was reached when the axial feeding was twice as much as the sealing distance. Also, the maximum amount of deformation rate happens shortly after the specimendie interface starts having relative motion, and it is at its slowest when the hydroforming reaches the fully-formed specimen’s shape.
Keywords:
Conical Tube Hydroforming (THF), Finite Element, Corner filling, axial feeding, plastic deformation
References:
[1] B.G. Marlapalle, R.S. Hingole, Predictions of formability parameters in tube hydroforming process. SN Applied Sciences, 3(6), 2021: 606. https://doi.org/10.1007/s42452-021-04533-4
[2] M. Ahmetoglu, T. Altan, Tube hydroforming: state-of-the-art and future trends. Journal of Materials Processing Technology, 98(1), 2000: 25–33. https://doi.org/10.1016/S0924-0136(99)00302-7
[3] L.H. Lang, Z.R. Wang, D.C. Kang, S.J. Yuan, S.H. Zhang, J. Danckert, K.B. Nielsen, Hydroforming highlights: sheet hydroforming and tube hydroforming. Journal of Materials Processing Technology, 151(1), 2004: 165-177. https://doi.org/10.1016/j.jmatprotec.2004.04.032
[4] G. Ngaile, Hydroforming Tribology, In: Q.J. Wang, Y.W. Chung, (Ed.), Encyclopedia of Tribology. Springer, US, 2013, pp.1765-1774.
[5] S. Milojević, D. Gročić, D. Dragojlović, CNG propulsion system for reducing noise of existing city buses. Journal of Applied Engineering Science, 14(3), 2016: 377-382. https://doi.org/10.5937/jaes14-10991
[6] S. Milojević, S. Savić, D. Marić, O. Stopka, B. Krstić, B. Stojanović, Correlation between Emission and Combustion Characteristics with the Compression Ratio and Fuel Injection Timing in Tribologically Optimized Diesel Engine. Tehnički Vjesnik, 29(4), 2022:1210–1219. https://doi.org/10.17559/TV20211220232130
[7] S. Milojević, B. Stojanović, Determination of tribological properties of aluminum cylinder by application of Taguchi method and ANNbased model. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 40(12), 2018: 571. https://doi.org/10.1007/s40430-018-1495-8
[8] L. Sun, C. Lin, Z. Fan, H. Li, G. Wang, G. Chu, Multistage Axial Hydro-Forging Sequence: A New Forming Approach for Manufacturing of Double-Stepped Tubes. Journal of Materials Engineering and Performance, 28(11), 2019:6800-6808. https://doi.org/10.1007/s11665-019-04444-x
[9] M. Jansson, L. Nilsson, K. Simonsson, On strain localisation in tube hydroforming of aluminium extrusions. Journal of Materials Processing Technology, 195(1), 2008: 3-14. https://doi.org/10.1016/j.jmatprotec.2007.05.040
[10] S. Kim, Y. Kim, Analytical study for tube hydroforming. Journal of Materials Processing Technology, 128(1), 2002: 232-239. https://doi.org/10.1016/S0924-0136(02)00456-9
[11] L. Galdos, J. Trinidad, N. Otegi, C. Garcia, Friction Modelling for Tube Hydroforming Processes – A Numerical and Experimental Study with Different Viscosity Lubricants. Materials, 15(16), 2022: 5655. https://doi.org/10.3390/ma15165655
[12] F. Mohammadi, M.M. Mashadi, Determination of the loading path for tube hydroforming process of a copper joint using a fuzzy controller. The International Journal of Advanced Manufacturing Technology, 43(1), 2009: 1-10. https://doi.org/10.1007/s00170-008-1697-9
[13] L. Shu-hui, B. Yang, Z. Wei-gang, L. Zhong-qin, Loading path prediction for tube hydroforming process using a fuzzy control strategy. Materials & Design, 29(6), 2008: 1110-1116. https://doi.org/10.1016/j.matdes.2007.06.008
[14] C. Zhang, W. Liu, L. Huang, C. Wang, H. Huang, L. Lin, P. Wang, Process analysis of biconvex tube hydroforming based on loading path optimization by response surface method. The International Journal of Advanced Manufacturing Technology, 112(9), 2021:2609-2622. https://doi.org/10.1007/s00170-020-06411-6
[15] S.L. Lin, F.K. Chen, Die Design and Axial Feeding in the Tube-Hydroforming Process, ASME 2010 International Manufacturing Science and Engineering Conference. American Society of Mechanical Engineers Digital Collection, October 12-15, 2010, Erie, Pennsylvania, USA, pp. 619-622. https://doi.org/10.1115/MSEC2010-34113
[16] Y. Jia, J. Li, J. Luo, Analysis and experiment on tube hydroforming in a rectangular crosssectional die. Advances in Mechanical Engineering, 9(5), 2017: 1687814017694831. https://doi.org/10.1177/1687814017694831
[17] C. Qi, L. Yan, S. Yang, S. Yuan, An optimization procedure for concave preform design in rectangular tube hydroforming. The International Journal of Advanced Manufacturing Technology, 120(7), 2022:5311-5324.
https://doi.org/10.1007/s00170-022-09080-9
[18] S.L. Lin, Z.W. Chen, F.K. Chen, A study on localized expansion defects in tube hydroforming. Journal of the Chinese Institute of Engineers, 41(2), 2018: 149-159. https://doi.org/10.1080/02533839.2018.1437367
[19] C.P. Nikhare, T. Buddi, N. Kotkunde, S.K. Singh, Effect of Die Velocity on Tube Deformation Mechanics During Low Pressure Tube Hydroforming Process Sequence Variation. International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers Digital Collection – ASME 2021, November 1-5, 2021, Virtual, Online, V02AT02A051. https://doi.org/10.1115/IMECE2021-70179
[20] P.V. Reddy, B.V. Reddy, P.J. Ramulu, An investigation on tube hydroforming process considering the effect of frictional coefficient and corner radius. Advances in Materials and Processing Technologies, 6(1), 2020: 84-103.
https://doi.org/10.1080/2374068X.2019.1707437
[21] H. Orban, S.J. Hu, Analytical modeling of wall thinning during corner filling in structural tube hydroforming. Journal of Materials Processing Tech, 1–3(194), 2007: 7-14. https://doi.org/10.1016/j.jmatprotec.2007.03.112
[22] G.T. Kridli, L. Bao, P,K, Mallick, Y. Tian, Investigation of thickness variation and corner filling in tube hydroforming. Journal of Materials Processing Tech, 3(133), 2003: 287-296. https://doi.org/10.1016/S0924-0136(02)01004-X
[23] C. Yang, G. Ngaile, Analytical model for planar tube hydroforming: Prediction of formed shape, corner fill, wall thinning, and forming pressure. International Journal of Mechanical Sciences, 50(8), 2008: 1263-1279.
https://doi.org/10.1016/j.ijmecsci.2008.05.006
[24] M. Jansson, L. Nilsson, K. Simonsson, Tube hydroforming of aluminium extrusions using a conical die and extensive feeding. Journal of Materials Processing Technology, 198(1), 2008: 14-21. https://doi.org/10.1016/j.jmatprotec.2007.09.043
[25] M.D. M, Experimental and Finite Element Study of the Hydroforming Bi-layered Tubular Component (Master’s Thesis). Dublin City University, Ireland, 2005.
[26] J.Y. Chen, Z.C. Xia, S.C. Tang, Corner Fill Modeling of Tube Hydroforming, ASME 2000 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers Digital Collection, November 5-10, 2000, Orlando, Florida, USA, pp. 635-640. https://doi.org/10.1115/IMECE2000-1863
[27] Y.M. Hwang, T. Altan, Finite element analysis of tube hydroforming processes in a rectangular die. Finite Elements in Analysis and Design, 39(11), 2003: 1071-1082. https://doi.org/10.1016/S0168-874X(02)00157-9
[28] B.V. Reddy, D. Kondayya, E.V. Goud, P.V. Reddy, Yield criterion influence on the formability prediction of SS 304 by tensile tests and bulge tests during tube hydroforming process. Multiscale and Multidisciplinary Modeling, Experiments and Design, 4(4), 2021: 293–302. https://doi.org/10.1007/s41939-021-00096-4
[29] A.T. Male, M.G. Cockcroft, A Method for the Determination of the Coefficient of Friction of Metals under Conditions of Bulk Plastic Deformation. Journal Institute of Metals, 93(38), 1964: 93-98.
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License (CC BY-NC 4.0)
Volume 9
Number 1
March 2024
Last Edition
Volume 9
Number 1
March 2024
How to Cite
Y. Jasim, G. Alwan, T. Othman, Theoretical and Experimental Study of Conical Tube Hydroforming with One-Sided Axial Feeding. Applied Engineering Letters, 7(3), 2022: 108–117.
https://doi.org/10.18485/aeletters.2022.7.3.3
More Citation Formats
Jasim, Y., Alwan, G., & Othman, T. (2022). Theoretical and Experimental Study of Conical Tube Hydroforming with One-Sided Axial Feeding. Applied Engineering Letters, 7(3), 108–117. https://doi.org/10.18485/aeletters.2022.7.3.3
Jasim, Yusra, et al. “Theoretical and Experimental Study of Conical Tube Hydroforming with One-Sided Axial Feeding.” Applied Engineering Letters, vol. 7, no. 3, 2022, pp. 108–17,
https://doi.org/10.18485/aeletters.2022.7.3.3.
Jasim, Yusra, Ghazwan Alwan, and Tahseen Othman. 2022. “Theoretical and Experimental Study of Conical Tube Hydroforming with One-Sided Axial Feeding.” Applied Engineering Letters 7 (3): 108–17. https://doi.org/10.18485/aeletters.2022.7.3.3.
Jasim, Y., Alwan, G. and Othman, T. (2022). Theoretical and Experimental Study of Conical Tube Hydroforming with One-Sided Axial Feeding. Applied Engineering Letters, 7(3), pp.108–117.
doi: 10.18485/aeletters.2022.7.3.3.
Journal Menu
Archive
THEORETICAL AND EXPERIMENTAL STUDY OF CONICAL TUBE HYDROFORMING WITH ONE-SIDED AXIAL FEEDING
Authors:
Yusra Jasim1
, Ghazwan Alwan1
, Tahseen Othman1
1Mechanical Engineering Department, Faculty of Engineering, Tikrit University, Iraq
Received: 12.06.2022.
Accepted: 26.09.2022.
Available: 30.09.2022.
Abstract:
Hydroforming has gained increasing attention in the manufacturing industry in recent years due to the demand for fast yet reliable production for parts, the applications of which accept a wide range of dimensional tolerances. In this study, tube hydroforming in conical dies has been analyzed. The study consists of two parts: computer simulations and experimental work. The simulation results were utilized to find the load paths which produce successful hydroforming for the selected tube specimens. Twelve load paths were identified and implemented with two friction coefficients and three pressure ranges. During the simulation process, the tubes were given an end movement that ranged from a sealing distance to twice that distance. The experimental work was implemented to verify some of the simulation results. The results showed that the best hydroforming limit was reached when the axial feeding was twice as much as the sealing distance. Also, the maximum amount of deformation rate happens shortly after the specimendie interface starts having relative motion, and it is at its slowest when the hydroforming reaches the fully-formed specimen’s shape.
Keywords:
Conical Tube Hydroforming (THF), Finite Element, Corner filling, axial feeding, plastic deformation
References:
[1] B.G. Marlapalle, R.S. Hingole, Predictions of formability parameters in tube hydroforming process. SN Applied Sciences, 3(6), 2021: 606. https://doi.org/10.1007/s42452-021-04533-4
[2] M. Ahmetoglu, T. Altan, Tube hydroforming: state-of-the-art and future trends. Journal of Materials Processing Technology, 98(1), 2000: 25–33. https://doi.org/10.1016/S0924-0136(99)00302-7
[3] L.H. Lang, Z.R. Wang, D.C. Kang, S.J. Yuan, S.H. Zhang, J. Danckert, K.B. Nielsen, Hydroforming highlights: sheet hydroforming and tube hydroforming. Journal of Materials Processing Technology, 151(1), 2004: 165-177. https://doi.org/10.1016/j.jmatprotec.2004.04.032
[4] G. Ngaile, Hydroforming Tribology, In: Q.J. Wang, Y.W. Chung, (Ed.), Encyclopedia of Tribology. Springer, US, 2013, pp.1765-1774.
[5] S. Milojević, D. Gročić, D. Dragojlović, CNG propulsion system for reducing noise of existing city buses. Journal of Applied Engineering Science, 14(3), 2016: 377-382. https://doi.org/10.5937/jaes14-10991
[6] S. Milojević, S. Savić, D. Marić, O. Stopka, B. Krstić, B. Stojanović, Correlation between Emission and Combustion Characteristics with the Compression Ratio and Fuel Injection Timing in Tribologically Optimized Diesel Engine. Tehnički Vjesnik, 29(4), 2022:1210–1219. https://doi.org/10.17559/TV20211220232130
[7] S. Milojević, B. Stojanović, Determination of tribological properties of aluminum cylinder by application of Taguchi method and ANNbased model. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 40(12), 2018: 571. https://doi.org/10.1007/s40430-018-1495-8
[8] L. Sun, C. Lin, Z. Fan, H. Li, G. Wang, G. Chu, Multistage Axial Hydro-Forging Sequence: A New Forming Approach for Manufacturing of Double-Stepped Tubes. Journal of Materials Engineering and Performance, 28(11), 2019:6800-6808. https://doi.org/10.1007/s11665-019-04444-x
[9] M. Jansson, L. Nilsson, K. Simonsson, On strain localisation in tube hydroforming of aluminium extrusions. Journal of Materials Processing Technology, 195(1), 2008: 3-14. https://doi.org/10.1016/j.jmatprotec.2007.05.040
[10] S. Kim, Y. Kim, Analytical study for tube hydroforming. Journal of Materials Processing Technology, 128(1), 2002: 232-239. https://doi.org/10.1016/S0924-0136(02)00456-9
[11] L. Galdos, J. Trinidad, N. Otegi, C. Garcia, Friction Modelling for Tube Hydroforming Processes – A Numerical and Experimental Study with Different Viscosity Lubricants. Materials, 15(16), 2022: 5655. https://doi.org/10.3390/ma15165655
[12] F. Mohammadi, M.M. Mashadi, Determination of the loading path for tube hydroforming process of a copper joint using a fuzzy controller. The International Journal of Advanced Manufacturing Technology, 43(1), 2009: 1-10. https://doi.org/10.1007/s00170-008-1697-9
[13] L. Shu-hui, B. Yang, Z. Wei-gang, L. Zhong-qin, Loading path prediction for tube hydroforming process using a fuzzy control strategy. Materials & Design, 29(6), 2008: 1110-1116. https://doi.org/10.1016/j.matdes.2007.06.008
[14] C. Zhang, W. Liu, L. Huang, C. Wang, H. Huang, L. Lin, P. Wang, Process analysis of biconvex tube hydroforming based on loading path optimization by response surface method. The International Journal of Advanced Manufacturing Technology, 112(9), 2021:2609-2622. https://doi.org/10.1007/s00170-020-06411-6
[15] S.L. Lin, F.K. Chen, Die Design and Axial Feeding in the Tube-Hydroforming Process, ASME 2010 International Manufacturing Science and Engineering Conference. American Society of Mechanical Engineers Digital Collection, October 12-15, 2010, Erie, Pennsylvania, USA, pp. 619-622. https://doi.org/10.1115/MSEC2010-34113
[16] Y. Jia, J. Li, J. Luo, Analysis and experiment on tube hydroforming in a rectangular crosssectional die. Advances in Mechanical Engineering, 9(5), 2017: 1687814017694831. https://doi.org/10.1177/1687814017694831
[17] C. Qi, L. Yan, S. Yang, S. Yuan, An optimization procedure for concave preform design in rectangular tube hydroforming. The International Journal of Advanced Manufacturing Technology, 120(7), 2022:5311-5324. https://doi.org/10.1007/s00170-022-09080-9
[18] S.L. Lin, Z.W. Chen, F.K. Chen, A study on localized expansion defects in tube hydroforming. Journal of the Chinese Institute of Engineers, 41(2), 2018: 149-159. https://doi.org/10.1080/02533839.2018.1437367
[19] C.P. Nikhare, T. Buddi, N. Kotkunde, S.K. Singh, Effect of Die Velocity on Tube Deformation Mechanics During Low Pressure Tube Hydroforming Process Sequence Variation. International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers Digital Collection – ASME 2021, November 1-5, 2021, Virtual, Online, V02AT02A051. https://doi.org/10.1115/IMECE2021-70179
[20] P.V. Reddy, B.V. Reddy, P.J. Ramulu, An investigation on tube hydroforming process considering the effect of frictional coefficient and corner radius. Advances in Materials and Processing Technologies, 6(1), 2020: 84-103. https://doi.org/10.1080/2374068X.2019.1707437
[21] H. Orban, S.J. Hu, Analytical modeling of wall thinning during corner filling in structural tube hydroforming. Journal of Materials Processing Tech, 1–3(194), 2007: 7-14. https://doi.org/10.1016/j.jmatprotec.2007.03.112
[22] G.T. Kridli, L. Bao, P,K, Mallick, Y. Tian, Investigation of thickness variation and corner filling in tube hydroforming. Journal of Materials Processing Tech, 3(133), 2003: 287-296. https://doi.org/10.1016/S0924-0136(02)01004-X
[23] C. Yang, G. Ngaile, Analytical model for planar tube hydroforming: Prediction of formed Y. Jasim et al. / Applied Engineering Letters Vol.7, No.3, 108-117 (2022)117 shape, corner fill, wall thinning, and forming pressure. International Journal of Mechanical Sciences, 50(8), 2008: 1263-1279. https://doi.org/10.1016/j.ijmecsci.2008.05.006
[24] M. Jansson, L. Nilsson, K. Simonsson, Tube hydroforming of aluminium extrusions using a conical die and extensive feeding. Journal of Materials Processing Technology, 198(1), 2008: 14-21. https://doi.org/10.1016/j.jmatprotec.2007.09.043
[25] M.D. M, Experimental and Finite Element Study of the Hydroforming Bi-layered Tubular Component (Master’s Thesis). Dublin City University, Ireland, 2005.
[26] J.Y. Chen, Z.C. Xia, S.C. Tang, Corner Fill Modeling of Tube Hydroforming, ASME 2000 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers Digital Collection, November 5-10, 2000, Orlando, Florida, USA, pp. 635-640. https://doi.org/10.1115/IMECE2000-1863
[27] Y.M. Hwang, T. Altan, Finite element analysis of tube hydroforming processes in a rectangular die. Finite Elements in Analysis and Design, 39(11), 2003: 1071-1082. https://doi.org/10.1016/S0168-874X(02)00157-9
[28] B.V. Reddy, D. Kondayya, E.V. Goud, P.V. Reddy, Yield criterion influence on the formability prediction of SS 304 by tensile tests and bulge tests during tube hydroforming process. Multiscale and Multidisciplinary Modeling, Experiments and Design, 4(4), 2021: 293–302. https://doi.org/10.1007/s41939-021-00096-4
[29] A.T. Male, M.G. Cockcroft, A Method for the Determination of the Coefficient of Friction of Metals under Conditions of Bulk Plastic Deformation. Journal Institute of Metals, 93(38), 1964: 93-98.
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License (CC BY-NC 4.0)
Volume 9
Number 1
March 2024
Last Edition
Volume 9
Number 1
March 2024