Journal articles: 'Aluminium alloys- Hydroforming'

1

Novotny, S., and P. Hein. "Hydroforming of sheet metal pairs from aluminium alloys." Journal of Materials Processing Technology 115, no. 1 (August 2001): 65–69. http://dx.doi.org/10.1016/s0924-0136(01)00766-x.

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Naeini, Hassan Moslemi, Golam Hosein Liaghat, S. J. Hashemi Ghiri, and S. M. H. Seyedkashi. "FE Simulation and Experimental Study of Tube Hydroforming Process for AA1050 Alloy at Various Temperatures." Advanced Materials Research 264-265 (June 2011): 96–101. http://dx.doi.org/10.4028/www.scientific.net/amr.264-265.96.

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Considering the necessity of using light weight, high strength and corrosion resistant materials, automotive and aerospace industries need to use advanced production technologies. Hydroforming has been regarded as one of the new technologies in forming of aluminium and magnesium alloys. These alloys have very low formability at room temperature which will be improved at elevated temperatures. In this paper, AA1050 aluminium alloy tube is numerically and experimentally investigated at different temperatures. Thickness distribution in forming zone is studied under different thermal conditions. Numerical results have been verified by experiments and there is a good agreement.

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Hojjati, M. H., M. Zoorabadi, and S. J. Hosseinipour. "Optimization of superplastic hydroforming process of Aluminium alloy 5083." Journal of Materials Processing Technology 205, no. 1-3 (August 2008): 482–88. http://dx.doi.org/10.1016/j.jmatprotec.2007.11.208.

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Michieletto, Francesco, Andrea Ghiotti, and Stefania Bruschi. "Novel Experimental Set-Up to Test Tubes Formability at Elevated Temperatures." Key Engineering Materials 611-612 (May 2014): 62–69. http://dx.doi.org/10.4028/www.scientific.net/kem.611-612.62.

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In the last ten years, the automotive sector presents large interest for light alloys tubes for structural and body car parts to reduce CO2 emissions. Tubes hydroforming is one of the most popular processes to obtain complex parts by using liquids as active part of the dies (i.e. water-or oil-based emulsions) with reduced costs of equipment and machines. However, when elevated temperatures should be used to increase the material formability, hydroforming processes are strongly limited due to the boiling point of liquids. The use of gas at elevated temperature in the so-called Hot Metal Gas Forming process (HMGF) has shown promising capabilities thanks to the increased formability and the possibility to form parts with lower pressures. The paper focuses on a novel experimental set-up to evaluate the tubes formability at high temperatures. Tubes are heated by electric current and air in pressure is used to form the material. Aluminium alloy AA6060 tubes specimens were used to test the experimental equipment and evaluate temperature and pressure ranges able to shape the material.

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Jansson, Mikael, Larsgunnar Nilsson, and Kjell Simonsson. "On strain localisation in tube hydroforming of aluminium extrusions." Journal of Materials Processing Technology 195, no. 1-3 (January 2008): 3–14. http://dx.doi.org/10.1016/j.jmatprotec.2007.05.040.

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Keigler, Michael, Herbert Bauer, David Harrison, and Anjali K. M. De Silva. "Enhancing the formability of aluminium components via temperature controlled hydroforming." Journal of Materials Processing Technology 167, no. 2-3 (August 2005): 363–70. http://dx.doi.org/10.1016/j.jmatprotec.2005.06.024.

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JIAO, Zhi-hui, Li-hui LANG, and Xiang-ni ZHAO. "5A06-O aluminium–magnesium alloy sheet warm hydroforming and optimization of process parameters." Transactions of Nonferrous Metals Society of China 31, no. 10 (October 2021): 2939–48. http://dx.doi.org/10.1016/s1003-6326(21)65704-7.

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Jansson, Mikael, Larsgunnar Nilsson, and Kjell Simonsson. "Tube hydroforming of aluminium extrusions using a conical die and extensive feeding." Journal of Materials Processing Technology 198, no. 1-3 (March 2008): 14–21. http://dx.doi.org/10.1016/j.jmatprotec.2007.09.043.

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Merklein, Marion, and Martin Grüner. "Mechanical Behaviour of Ceramic Beads Used as Medium for Hydroforming at Elevated Temperatures." Key Engineering Materials 410-411 (March 2009): 61–68. http://dx.doi.org/10.4028/www.scientific.net/kem.410-411.61.

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The need of light weight construction for high efficient vehicles leads to the use of new materials like aluminium and magnesium alloys or high strength and ultra high strength steels. At elevated temperatures the formability of steel increases as the flow stresses decrease. Forming high complex geometries like chassis components or components of the exhaust system of vehicles can be done by hydroforming. The hydroforming process by oils is limited to temperatures of approximately 300 °C and brings disadvantages of possible leakage and fouling. Using granular material like small ceramic beads as medium could be an approach for hydroforming of ultra high strength steels like MS W1200 and CP W800 at temperatures up to 600 °C. The material properties of granular material are in some points similar to solid bodies, in other points similar to liquids. For understanding and simulation of the behaviour of the medium a basic characterisation of ceramic beads with different ball diameters is necessary. Powder mechanics and soil engineering give ideas for experimental setups. For the conversion of these approaches on the one hand the behaviour of the ceramic beads itself has to be characterized, on the other hand the contact between a blank and the beads have to be investigated. For the tests three different kinds of spheres with a diameter between 63 microns and 850 microns are used. In unidirectional compression test compressibility, pressure distribution in compression direction and transversal compression direction and the effect of bead fracture are investigated. The tests are carried out at different compression velocities and for multiple compressions. For determination of friction coefficients between blank and beads and determination of shear stress in bulk under compression a modified Jenike-Shear-Cell for use in universal testing machines with the possibility of hydraulic compression of the beads is built up. The gained data can be used for material modelling in ABAQUS using Mohr-Coulomb or Drucker-Prager model.

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Lee, Myeong Han, Young Chul Shin, and Duk Jae Yoon. "Effect of Heat Treatment Conditions on Tube Hydroforming Characteristics of Aluminum Alloy." Key Engineering Materials 535-536 (January 2013): 275–78. http://dx.doi.org/10.4028/www.scientific.net/kem.535-536.275.

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Tube hydroforming is a metal forming technology that utilizes internal pressure and axial compressive loads to generate designed product shapes with complex sections from tubular materials. The tube hydroforming process has been used in the automotive, aircraft, and bicycle industries for many years. With the pursuit of lighter bicycles, aluminum alloys have been utilized as an alternative to steel. To obtain adequate strength, the aluminum alloys should undergo heat treatment processes before being used. However, the mechanical properties of the alloys vary with the tempering conditions. This paper aims to evaluate the effects of tube hydroforming characteristics on different kinds of tempered aluminum alloys. Based on numerical simulations, suitable tube hydroforming processing conditions for each tempered aluminum alloy are suggested.

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Turkoz, Mevlut, Selcuk Halkacı, and Muammer Koç. "The Effect of Temperature and Strain-Rate Sensitivity on Formability of AA 5754." Applied Mechanics and Materials 217-219 (November 2012): 1596–601. http://dx.doi.org/10.4028/www.scientific.net/amm.217-219.1596.

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Aluminum alloys have limited usage because of their limited formability at room temperatures. In order to design and develop more parts made of aluminum, new forming techniques such as hydroforming, warm forming and warm hydroforming have been researched to overcome the low formability issues. This, in turn, necessitates understanding and modeling the behavior of aluminum alloys at different temperatures and strain rates. This paper deals with the investigation of the effect of temperature and strain rate sensitivity on the formability of AA 5754 aluminum alloy. Tensile tests were carried out at temperatures of 20,100,180 and 260°C and forming rates of 25, 100 and 250 mm/min. The mechanical properties and flow curves were obtained and the strain rate sensitivities were calculated at different strains and temperatures. The effects of temperature and strain rate sensitivity on the formability were introduced.

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Khalfallah, Ali, Temim Zribi, and Hedi Belhadj Salah. "Application of Tube Hydroforming in Square Cross-Section Die for Inverse Identification Method Validation." Key Engineering Materials 554-557 (June 2013): 966–73. http://dx.doi.org/10.4028/www.scientific.net/kem.554-557.966.

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Tube hydroforming processes are an excellent way for manufacturing reduced weight parts with complex shapes in widespread fields. Accurate numerical simulation of tube hydroforming process is particularly based on precise material parameters deduced from experimental tests. The free bulge test is widely employed for the parameter identification of tubular material behavior models by means of analytical [1] and numerical methods [2]. In this context, an inverse identification methodology using free bulge tests was developed. These tests were carried out by means of a new home-designed and manufactured bulge forming machine. The objective of this work is the validation of the inverse identification method using tube hydroforming in square cross-section die. The analysis of this particular hydroforming process with respect to material parameters is performed. For this purpose, circular section tubes made of low carbon steel S235 and aluminum alloy AA6063-O are hydroformed against square-cross sectional die using our bulge forming machine. Afterwards, FE model is constructed to simulate square-sectional hydroformed parts. The influence of some parameters, such as strain hardening exponent, anisotropy parameter and friction coefficient, on numerical square cross-sectional hydroformed part thickness is analyzed. It permits to assess the sensitivity of the thickness relative to used material parameters in the FE model. In order to validate the inverse identification procedure for both materials, experimental thicknesses along the profile of cross-sectional hydroformed parts are measured and compared with the corresponding numerical thicknesses predicted by FE model. It is proven after analyzing the obtained results that the chosen response, i.e. thickness distribution along the profile of the tube hydroforming against the square cross-section die, used for the validation is sensitive to the identified material properties. Particularly, it is demonstrated for low carbon steel S235 that numerical thickness is in good agreement with experimental data. However, for aluminum alloy AA6063-O, a discrepancy between experimental and predicted thicknesses is noticed. Anyway, it is demonstrated that inverse identification approach leads to sufficiently accurate parameters used for numerical tube hydroforming simulations. Furthermore, it seems that Hill48’s yield criterion is more suitable for describing steels plastic behavior than aluminum alloys for tube hydroforming processes. Concerning aluminum alloy, certainly the choice of appropriate yield criterion is of paramount importance on the prediction of tubular plastic behavior in tube hydroforming. Consequently, it is shown that the use of simple tube hydroforming in square-section die is suitable for the validation of FE model which is identified by inverse method using free bulge test.

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Kim, B. J., K. H. Choi, K. S. Park, Chester J. van Tyne, and Young Hoon Moon. "Effect of the Surface Defects on Hydroformability of Aluminum Alloys." Key Engineering Materials 340-341 (June 2007): 587–92. http://dx.doi.org/10.4028/www.scientific.net/kem.340-341.587.

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Extruded aluminum alloys, which are highly versatile, have relatively modest prototyping cost, good strength and corrosion resistance. Because there is no weld seam, the circumferential mechanical properties may be uniform and advantageous for hydroforming. However, surface defects such as die lines and pick-up can be generated during the extrusion especially due to imperfections on the die surface. In this study, the extent of the crack propagation caused by die lines is evaluated according to the deformed shape of the tube in hydroforming process. And when forming a extruded aluminum tube, the deformed surface of the tube frequently becomes rougher with increasing plastic strain. This is well known as orange peel phenomenon and it has a significantly effect not only on the surface quality of a final product but also on the forming limit. To evaluate the effects of the orange peel on the hydroformability, the inter-stage polishing has been performed. Through the several tests including hydroforming test, the effect of surface defects on the hydroformabilities are well defined.

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Loukus, Adam R., Ghatu Subhash, and Mehdi Imaninejad. "Optimization of Material Properties and Process Parameters for Tube Hydroforming of Aluminum Extrusions." Journal of Engineering Materials and Technology 129, no. 2 (July 31, 2006): 233–41. http://dx.doi.org/10.1115/1.2400259.

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Analysis of process optimization for hydroforming of central-bulge and T-branch from AA6063 tubes is conducted for W-temper and T4 heat-treated conditions. Systematic characterization of AA6063 mechanical properties as a function of aging time was also conducted. It was found that hydroforming in the W temper facilitates forming of a bigger T branch (due to available greater ductility), but limits the strength (hardness) of the final component compared to that formed in the T4 condition. By optimizing the material heat-treatment conditions and the process parameters during hydroforming, strains well in excess of the traditional forming limits can be achieved in the finished components. The relevant microstructural kinetics during hydroforming of the above two geometries in the two heat treated conditions and the associated strengthening mechanisms in aluminum alloys are discussed.

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Reddy, P. Venkateshwar, B. Veerabhadra Reddy, and P. Janaki Ramulu. "Evolution of Hydroforming Technologies and Its Applications — A Review." Journal of Advanced Manufacturing Systems 19, no. 04 (December 2020): 737–80. http://dx.doi.org/10.1142/s0219686720500341.

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Advanced forming technologies have been evolving at a rapid pace with the products applicability in the industrial fields of aerospace and automobile especially for the materials like aluminum and titanium alloys (light weight) and ultra-high strength steels. Innovative forming methods like hydroforming (tube and sheet) have been proposed for industries throughout the world. The ever-increasing needs of the automotive industry have made hydroforming technology an impetus one for the development and innovations. In this paper, the review on various developments towards lightweight materials for different applications is presented. The influencing process parameters considering the different characteristics of the tube and sheet hydroforming process have also been presented. General ideas and mechanical improvements in sheet and tube hydroforming are given late innovative work exercises. This review will help researchers and industrialists about the history, state of the art in hydroforming technologies of the lightweight materials.

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Günaydın, Ahmet Can, Mehmet Halkacı, Fatih Ateş, and Hüseyin Selçuk Halkacı. "Experimental Research of the Usability on Double Acting Intensifiers in Hydroforming." MATEC Web of Conferences 220 (2018): 04006. http://dx.doi.org/10.1051/matecconf/201822004006.

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The hydroforming method is especially used for forming lightweight materials like aluminum, magnesium alloys, high strength steels or materials that have limited formability. Intensifiers are the most important component of hydroforming presses. Nowadays single-acting intensifiers are used in hydroforming presses. Single-acting intensifiers provide pressurized liquid by forwarding movement of the piston through one direction and their volumes are limited. The mass of the intensifiers increases significantly depending on their liquid volume capacity and this causes high manufacturing costs. For this reason, two or more single-acting intensifiers which bridged in a parallel circuit are used to manufacture bigger products that require a high volume of liquid. But this method is not an economical solution. So double-acting intensifiers can overcome this problem. The pressurized liquid can be obtained during both forward and backward movement of the piston in double-acting intensifiers which work like a pump. This is why double-acting intensifiers have no volume limit on the contrary of single-acting intensifiers. Yet there are sudden pressure drops in double-acting intensifiers caused by returning movements of the piston to pressurize liquid again. This pressure drops cause some problems to use double-acting intensifiers on hydroforming method. The situation of solving this problem to use double-acting intensifiers on the hydroforming method can eliminate limited volume problem and decrease investment cost of hydroforming presses. In this study, the usability of double-acting intensifiers on hydroforming with die method was investigated. Because of the existing hydroforming press, used in experiments, doesn’t contain any double-acting intensifiers, pressure drops obtained by single-acting intensifier to perform simulated experiment. A die was designed and manufactured to synchronize the blank holder force with pressure drops. This die was integrated on the hydroforming press, located on Selcuk University Hydroforming Laboratory, for the success of the process. Performance of improved system was measured as well as repeatability of applying process parameters and product’s geometry were determined. The AA5754 aluminum alloy used processes, both single- and double-acting intensifier, were compared. Limiting drawing ratios were determined for all processes. It is obtained that pressure drops have no negative influence on formability. Moreover, there is no difference observed in thickness distribution which is an indicator of product’s quality and strength. However, when geometric accuracy was investigated then noticed that the pressure drops count has a good influence on product radius. 5.96 mm product radiuses on the process with single-acting intensifier was obtained 5.92 and 5.10 mm by using double-acting intensifier increasing pressure drop’s frequency.

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Altan, Taylan, Serhat Kaya, and Yingyot Aue-u-Ian. "Forming Al and Mg Alloy Sheet and Tube at Elevated Temperatures." Key Engineering Materials 344 (July 2007): 317–24. http://dx.doi.org/10.4028/www.scientific.net/kem.344.317.

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Experimental investigation on the formability limits of aluminum and magnesium alloys are conducted through hydraulic bulging and deep drawing. New tube hydroforming tooling was designed and the submerged tool concept is introduced. Tube hydroforming experiments were conducted with and without axial feed by using AA6061 tubes. The formability of Mg AZ31-O sheets are determined by hydraulic bulging using similar submerged tool. Finally the effect of temperature and initial blank size on the attainable highest punch velocity is investigated and round cups from Mg AZ31-O were successfully formed in a heated tool with punch speeds up to 300 mm/s.

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Wang, Shao Hua, Li Hui Lang, and Li Jing Lin. "Investigation on the Energy Efficiency of Innovative Hybrid Impact Hydroforming." Advanced Materials Research 989-994 (July 2014): 1282–85. http://dx.doi.org/10.4028/www.scientific.net/amr.989-994.1282.

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The innovative hybrid impact hydroforming (IHF) technology use high energy forming complex parts in very short time which can improving forming quality of hardforming materials like Aluminum alloy widely used in automotive and aircraft industries. The impact hydroforming technology means the most features are formed by hydroforming and the small features are rapidly reshaped by high intensity impact energy in a very short time after the traditional hydroforming. Thus, the impact energy is the most important parameter of Innovative Hybrid Impact Hydroforming. Using numerical simulation software MSC.PATRAN/DYTRAN, the whole system of hybrid impact hydroforming apparatus was analyzed. The initial gas pressure and the mass of hammer directly affect the energy efficiency. The results show greater initial gas pressure will linear increase the energy output. Moreover, the bigger mass of hammer will reduce the velocity of hammer, but it still increase the energy output. Therefore, the research is very useful for improving energy efficiency of IHFand widing its application.

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Kim, B. J., S. M. Son, K. S. Park, and Young Hoon Moon. "The Effects of the Heating Conditions on the Hydro-Formability of the Aluminum Alloys at High Temperatures." Materials Science Forum 475-479 (January 2005): 3307–10. http://dx.doi.org/10.4028/www.scientific.net/msf.475-479.3307.

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Modern automobiles are built with a steadily increasing variety of materials and semifinished products. The traditional composition of steel sheet and cast iron is being replaced with other materials such as aluminum and magnesium. But low formability of these materials has prevented the application of the automotive components. The formability can be enhanced by conducting the warm hydroforming using induction heating device which can raise the temperature of the specimen very quickly. The specimen applied to the test is AA6061 extruded tubes which belong to the age-hardenable aluminum alloys. But in the case of AA6061 age hardening occurs at room temperature or at elevated temperatures before and after the forming process. In this study the effects of the heating condition such as heating time, preset temperature, holding time during die closing and forming time on the hydroformability are analyzed to evaluate the phenomena such as dynamic strain hardening and ageing hardening at high temperatures after the hydroforming process.

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Abrantes, Jorge Paiva, Carlos Eduardo Célia de Lima, and Gilmar Ferreira Batalha. "Numerical simulation of an aluminum alloy tube hydroforming." Journal of Materials Processing Technology 179, no. 1-3 (October 2006): 67–73. http://dx.doi.org/10.1016/j.jmatprotec.2006.03.069.

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Palumbo, G., A. Piccininni, P. Guglielmi, and G. Di Michele. "Warm HydroForming of the heat treatable aluminium alloy AC170PX." Journal of Manufacturing Processes 20 (October 2015): 24–32. http://dx.doi.org/10.1016/j.jmapro.2015.09.012.

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Oliveira, D. A., and M. J. Worswick. "Tube bending and hydroforming of aluminium alloy S-rails." International Journal of Material Forming 2, no. 3 (April 4, 2009): 197–215. http://dx.doi.org/10.1007/s12289-009-0404-1.

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Cai, Gaoshen, Chuanyu Wu, and Dongxing Zhang. "Investigation on the Effect of Type of Cooling on the Properties of Aluminum Alloy during Warm/Hot Hydromechanical Deep Drawing." Symmetry 10, no. 9 (August 26, 2018): 362. http://dx.doi.org/10.3390/sym10090362.

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The warm sheet cylindrical deep drawing experiment of aluminum alloy was carried out and macro-mechanical properties and microstructure evolution of hydro-formed cups with different cooling medium were analyzed, which aimed to investigate the effects of different types of cooling on mechanical properties and microstructure of cylindrical cups hydro-formed by warm Hydro-mechanical Deep Drawing (HDD). Results show that, under the condition of warm hydroforming, the mechanical properties such as yield stress and ultimate strength were influenced very little by air or water cooling. Grain coarsening of these hydro-formed cups can be inhibited to a certain extent with subsequent rapid water cooling. Moreover, it shows that the processing with warm sheet hydroforming and subsequent rapid cooling of 7075-O aluminum alloy has a positive significance in maintaining the stability of macro mechanical properties and inhibiting the degradation of the microstructure of materials.

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Djavanroodi, Faramarz, D. Sharam Abbasnejad, and E. Hassan Nezami. "Deep Drawing of Aluminum Alloys Using a Novel Hydroforming Tooling." Materials and Manufacturing Processes 26, no. 5 (May 2011): 796–801. http://dx.doi.org/10.1080/10426911003720722.

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Jansson, Mikael, Larsgunnar Nilsson, and Kjell Simonsson. "On constitutive modeling of aluminum alloys for tube hydroforming applications." International Journal of Plasticity 21, no. 5 (May 2005): 1041–58. http://dx.doi.org/10.1016/j.ijplas.2004.06.005.

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Kim, B. J., K. S. Park, J. S. Ryu, and Young Hoon Moon. "Experimental Analysis for the Tubular Hydroformability of Aluminum Alloys at Elevated Temperatures." Materials Science Forum 475-479 (January 2005): 4215–18. http://dx.doi.org/10.4028/www.scientific.net/msf.475-479.4215.

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Aluminum alloys have a high potential for weight reduction in automotive and other applications, but they have a relatively low tubular hydroformability at room temperature. Hot working processes are commonly used for bulk metal forming, such as forging and rolling, but rare in sheet metal forming like hydroforming. The hydroformability of aluminum alloys can however be enhanced significantly at elevated temperatures. In this study, the hydroformability of aluminum alloys at elevated temperatures has therefore been investigated by using a specially designed induction heating system. The formability characteristics at high temperatures were obtained by a T-fitting forming test as well as a free bulge test. The effects of the process parameters such as an internal pressure and temperature on tubular forming limits have mainly been investigated and the results are presented in this paper

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Zhang, Fei Fei, Jun Chen, Jie Shi Chen, Xin Hai Zhu, and Shi Jian Yuan. "A Modified Shell Element Model Combined with Yld91 Yield Function in Simulating Aluminum Alloy Applied Hydroforming." Key Engineering Materials 639 (March 2015): 435–42. http://dx.doi.org/10.4028/www.scientific.net/kem.639.435.

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Hydroforming has been used widely across many industrial fields. Large applied pressure during hydroforming makes it necessary to consider the influence of normal stress in the thickness direction, while in FE simulation, the use of traditional shell element based upon plane-stress assumption is not appropriate in such cases. Here, the traditional shell element is modified by changing the constitutive relation which took into account the normal stress in the thickness direction, and the modified shell element formula is combined with Yld91 yield function to simulate the forming process of Aluminium alloy. Then the element formulation and material model is implemented into the FE code Ls-Dyna by means of USER interface. Two examples are carried out and good correlations are obtained when compared to the traditional shell element and solid element.

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Muñoz-Rubio, Aurelio, David Bienvenido-Huertas, Francisco Javier Bermúdez-Rodríguez, and Manuel Tornell-Barbosa. "Design Optimization of the Aeronautical Sheet Hydroforming Process Using the Taguchi Method." Applied Sciences 9, no. 9 (May 10, 2019): 1932. http://dx.doi.org/10.3390/app9091932.

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The aluminium alloy sheet forming processes forging in rubber pad and diaphragm presses (also known as hydroforming processes) are simple and economical processes adapted to aeronautical production. Typical defects of these processes are elastic recovery, necking, and wrinkling, and they present difficulties in control mainly due to property variations of the sheet material that take place during the process. In order to make these processes robust and unresponsive to material variations, a multiobjective optimization methodology based on the Taguchi method is proposed in the present study. The design of experiments and process simulation are combined in the methodology, using the nonlinear finite element method. The properties of sheet material are considered noise factors of the hydroforming process, the objective being to find a combination of the control factors that causes minimal defects to noise factors. The methodology was applied to an AA2024-T3 aluminium alloy sheet of 1 mm thickness stamping process in a diaphragm press. The results allowed us to establish the optimal pressure values, friction coefficient between sheet and block, and friction coefficient between sheet and rubber to reduce the elastic recovery variations and the minimal thickness before noise facts.

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Paunoiu, Viorel, Florian Pereira, Virgil Gabriel Teodor, and Catalina Maier. "Investigation of Hydroforming Technology for Manufacturing an Auto Complex Part." Materials Science Forum 957 (June 2019): 138–47. http://dx.doi.org/10.4028/www.scientific.net/msf.957.138.

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Hydroforming process is used for obtaining different kinds of sheet metal components in an economic manner in terms of time and costs reduction and increase of the product quality. This paper deals with the application of this type of technology for manufacturing a rotational auto part from aluminium alloy. An experimental tool for hydroforming with rubber membrane was used. A set of dies with different geometries has been designed and constructed. Experiments have been conducted for investigation the ability of transferring features from the die onto the blank surface for different die geometries and pressures. The hydroformed part was measured using CMM. Based on the experimental data a numerical model was designed. FEM using Abaqus solver was used for investigated the part geometry and the effective stress distribution under various pressures conditions and dies geometries. The experimental and simulation results show the feasibility of applying the sheet hydroforming process in order to obtain a sound product.

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Dilmec, Murat. "Numerical Investigation of Manufacturability of Various Compound Shapes Using Sheet Hydroforming Process." Applied Mechanics and Materials 217-219 (November 2012): 1682–87. http://dx.doi.org/10.4028/www.scientific.net/amm.217-219.1682.

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The demand for complex sheet parts has increased more and more in the modern lightweight construction, especially in the automotive industry. Complex drawn sheet parts can be usually achieved in one step with using the hydroforming technology. As the demand for the complex products increase, the need of hydroforming process will greatly expanded around the world due to its many advantages. Complex parts have many convex and/or concave features on it. The shapes, dimensions and the positions of the features are important for manufacturing high quality products. So understanding these geometrical parameters on the product quality has great importance. In this study, the effects of the geometrical parameters of the complex stepped parts on the manufacturability by using sheet hydroforming process were numerically investigated for AA5754 aluminum alloy and some of results were experimentally confirmed.

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Lin, Dong Yan, and Yi Li. "Numerical Simulation Research on Springback Controlling Methods of Aluminum Alloy Panel during Hydroforming." Applied Mechanics and Materials 851 (August 2016): 163–67. http://dx.doi.org/10.4028/www.scientific.net/amm.851.163.

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The hydroforming process of the aluminum alloy panel was simulated by the software DYNAFORM. The effects of process parameters (blank holder force, depth of panel and height of draw bead) on springback of the aluminum alloy were investigated. The max springback of the panel was analyzed by weighted scoring method. Then the process parameters were synthetically optimized for the max positive and negative springback. The results showed that the height of draw bead affects obviously the comprehensive springback of the panel. The optimization of the process parameters obtained by the orthogonal experiment can effectively reduce the max springback of the panel.

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Gies, Soeren, Christian Weddeling, Lukas Kwiatkowski, and A. Erman Tekkaya. "Groove Filling Characteristics and Strength of Form-Fit Joints Produced by Die-Less Hydroforming." Key Engineering Materials 554-557 (June 2013): 671–80. http://dx.doi.org/10.4028/www.scientific.net/kem.554-557.671.

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The manufacturing of modern lightweight structures and the implementation of multi material concepts, for example in automotive engineering, entails appropriate joining technologies. The absence of additional connection elements or filling materials as well as the possibility to join dissimilar metals are basic requirements in this field of application to reach the aspired weight reduction. In case of tubular joints the die-less hydroforming process meets these demands and thus makes it an interesting alternative to conventional welding and riveting processes. The present work focuses on form fit joints produced by die-less hydroforming. It provides a verification of a previously presented analytical approach that allows the calculation of the working fluid pressure required to bulge the tube material into the groove of the outer joining partner. For that purpose, the groove filling characteristics of joined specimens with different groove geometries are analyzed. Here both joining partners were made of the aluminum alloy EN AW-6060. Additionally the connection strength of the joined specimens are determined using tensile tests. The results prove that the groove angle is the main influencing factor on the connection strength and that it can be used for an ordinal comparison of different groove geometries.

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Zhou, Bin-Jun, and Yong-Chao Xu. "Wrinkle Behavior of Hydroforming of Aluminum Alloy Double-Layer Sheets." JOM 68, no. 12 (July 13, 2016): 3201–7. http://dx.doi.org/10.1007/s11837-016-2025-8.

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Nguyen, Ba Nghiep, Kenneth I. Johnson, and Mohammad A. Khaleel. "Analysis of Tube Hydroforming by Means of an Inverse Approach1." Journal of Manufacturing Science and Engineering 125, no. 2 (April 15, 2003): 369–77. http://dx.doi.org/10.1115/1.1559166.

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This paper presents a computational tool for the analysis of freely hydroformed tubes by means of an inverse approach. The formulation of the inverse method developed by Guo et al. [1] is adopted and extended to the tube hydroforming problems in which the initial geometry is a round tube submitted to hydraulic pressure and axial feed at the tube ends (end-feed). A simple criterion based on a forming limit diagram is used to predict the necking regions in the deformed workpiece. Although the developed computational tool is a stand-alone code, it has been linked to the Marc finite element code for meshing and visualization of results. The application of the inverse approach to tube hydroforming is illustrated through the analyses of the aluminum alloy AA6061-T4 seamless tubes under free hydroforming conditions. The results obtained are in good agreement with those issued from a direct incremental approach. However, the computational time in the inverse procedure is much less than that in the incremental method.

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Xiao, X. T., C. X. Qi, F. Wu, Z. R. Zhang, M. T. Chen, F. Q. Zhou, X. L. Chen, and X. S. Zhou. "Study on hybrid hydroforming process of sheet metal with multi-concave and convex surface parts." IOP Conference Series: Materials Science and Engineering 1270, no. 1 (December 1, 2022): 012035. http://dx.doi.org/10.1088/1757-899x/1270/1/012035.

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By means of numerical simulation and experimental, the liquid filling forming process of an aluminum alloy double concave and convex curved sheet part was studied. The quality of forming parts, especially the thinning rate, is compared and studied during different hydroforming process. The results show that the thinning rate of the product is more than 25% regardless of the passive or active liquid filling drawing. However, the maximum thinning rate of the product is less than 20% when the hybrid hydroforming is carried out in a set of die with passive liquid filling in sequence, followed by pulsating reverse liquid filling. The method has reference significance for improving the forming quality of the parts with concave and convex surface of thin plate.

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Wang, Yong Ming, Li Hui Lang, and Ya Su Xie. "Numerical and Experimental Investigation into the Aluminum Alloy Irregular Box Sheet Hydroforming Process." Advanced Materials Research 602-604 (December 2012): 1846–49. http://dx.doi.org/10.4028/www.scientific.net/amr.602-604.1846.

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Sheet hydroforming process of one irregular box with unequal height and flat bottom was investigated by numerical simulation and experiment. The effect of blank shape and pressure loading path on the forming result was discussed. The key process parameter was optimized. The results have shown that the round blank is the best shape blank. The part can be formed with the appropriate blank shape and die cavity pressure.

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Wang, Chu, Min Wan, and Wen Nan Yuan. "Numerical and Experimental Study on Sheet Hydroforming of 2A12 Aluminum Alloy." Key Engineering Materials 716 (October 2016): 981–87. http://dx.doi.org/10.4028/www.scientific.net/kem.716.981.

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In this paper, the sheet hydroforming process of 2A12 aluminum alloy with uniform die cavity pressure on to the blank is proposed and investigated both primarily through the finite element method (FEM) and experiments. The influence of the die cavity pressure curve on the quality of the products was explored and the measures to promote the sheet formability were discussed. The results from the studied case indicate that the profile of the cavity pressure was one of the fundamental parameters directly related to the product's quality and precision. Excessive or insufficient initial pressure is not conducive for the reduction of wall thickness thinning and guarantee of wall thickness uniformity. And the wall thickness thinning is reduced and the thickness evenness is improved by increasing the maximum cavity pressure within a proper range. Moreover, an optimum cavity pressure curve generated by the numerical and experimental methods was properly applied in forming the aluminum alloy part without rupture and with slight wrinkle in the flange area. The study demonstrates that the results of simulations based on the identified parameters were in reasonable agreement with those from experiments.

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Modi, Bharatkumar, and Digavalli Ravi Kumar. "Effect of Friction and Lubrication on Formability of AA5182 Alloy in Hydroforming of Square Cups." Materials Science Forum 762 (July 2013): 621–26. http://dx.doi.org/10.4028/www.scientific.net/msf.762.621.

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nfluence of friction and lubrication on formability of an aluminium alloy (AA5182) in hydroforming of square cups has been studied experimentally and numerically. Three friction conditions were created at the blank-die interface using hydraulic oil, Teflon and dry condition (no lubrication). Maximum thinning and minimum radius at the cup corners were taken as criteria for formability evaluation. Formability improved to a great extent with Teflon sheet as the lubricant. Lower friction allowed better draw-in of the material with higher uniformity of strain distribution and the maximum pressure that the material can sustain has significantly increased.

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Lu, Xin, and Hong Jin. "Combined process of hydroforming and electro hydraulic precision reshaping for aluminium alloy." Procedia Manufacturing 15 (2018): 907–14. http://dx.doi.org/10.1016/j.promfg.2018.07.406.

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WANG, Xiao-song, Shi-jian YUAN, Peng SONG, and Wen-cai XIE. "Plastic deformation on hydroforming of aluminum alloy tube with rectangular sections." Transactions of Nonferrous Metals Society of China 22 (December 2012): s350—s356. http://dx.doi.org/10.1016/s1003-6326(12)61730-0.

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GUAN, Y., F. POURBOGHRAT, and F. BARLAT. "Finite element modeling of tube hydroforming of polycrystalline aluminum alloy extrusions." International Journal of Plasticity 22, no. 12 (December 2006): 2366–93. http://dx.doi.org/10.1016/j.ijplas.2006.04.003.

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Manabe, Ken-ichi, Masamitsu Suetake, Hiroshi Koyama, and Ming Yang. "Hydroforming process optimization of aluminum alloy tube using intelligent control technique." International Journal of Machine Tools and Manufacture 46, no. 11 (September 2006): 1207–11. http://dx.doi.org/10.1016/j.ijmachtools.2006.01.028.

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Chu, Guannan, Feng Li, and Wenjian Liu. "Deformation characteristics during Y-shaped tube hydroforming of 6061 aluminum alloy." JOM 63, no. 2 (February 2011): 81–84. http://dx.doi.org/10.1007/s11837-011-0034-1.

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Lang, Lihui, Shijian Yuan, Xiaosong Wang, Z. R. Wang, Zhuang Fu, J. Danckert, and K. B. Nielsen. "A study on numerical simulation of hydroforming of aluminum alloy tube." Journal of Materials Processing Technology 146, no. 3 (March 2004): 377–88. http://dx.doi.org/10.1016/j.jmatprotec.2003.11.031.

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Chu, Guannan, and Wenjian Liu. "Experimental Observations of 5A02 Aluminum Alloy in Electromagnetically Assisted Tube Hydroforming." JOM 65, no. 5 (March 13, 2013): 599–603. http://dx.doi.org/10.1007/s11837-013-0578-3.

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Eladl, Abdelkhalik, Ossama B. Abouelatta, Magdy Samuel, and Tawakol A. Enab. "Effect of Hydroforming Drawing Cups on Thickness Variation and Surface Roughness." International Journal of Engineering Research in Africa 59 (March 15, 2022): 1–18. http://dx.doi.org/10.4028/p-ki740n.

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Recently, hydroforming was developed to address the emerging problems encountered by the conventional rigid tool-based deep drawing process. Hydroforming is a specialized type of die forming process, that uses a rigid die while the pressure provided by the liquid acts as a punch to shape the sheet metal. The current paper is directed to study the hydroforming process numerically and experimentally as a means for shaping aluminum alloy sheets based on the quality of product thickness variation and surface roughness. Moreover, it offered a comparative investigation of the experimental and numerical findings of this process. Therefore, thickness variation has been calculated numerically by designing a numerical model using Marc software which fits in large deformation simulation. On the other hand, thickness variation and surface roughness were measured experimentally along drawn cups and compared with the numerical results. The numerical results of thickness variation are matched with the experimental results. Furthermore, surface roughness was measured and compared before and after drawing at five regions. Since there is no contact between the upper side of a cup and any metallic parts, surface roughness depends only on the effect of plastic strain and was found to be increased in all regions.

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Tönshoff, Hans Kurt, J. Bunte, O. Meier, and L. Engelbrecht. "Deformation Behaviour of Sheet Metals in Laser Assisted Hydroforming Processes." Advanced Materials Research 6-8 (May 2005): 361–68. http://dx.doi.org/10.4028/www.scientific.net/amr.6-8.361.

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Cupping small form elements in hydroforming processes requires high work pressures and clamping forces and thus high capital investments for presses. Localised laser heating used during sheet metal hydroforming processes should reduce the necessary work pressure. By reducing the yield strength and the strain hardening using local heating, small form elements can be formed at very low pressures of 2 MPa, whereas cold forming requires pressures which are 20-50 times higher. Besides the proportion of forming temperature and work pressure, temperature distribution is very important and can be adjusted using a special laser beam forming optic or a scanning processing head. Line network analysises were carried out showing great improvements in the resulting plastic deformation distribution. In order to characterise the general improvement of the material’s formability, forming limit curves (FLC) were generated using the bulge-test. The results approve the extended forming limit of the laser assisted warm cupping process. Moreover, the mechanical properties and the grain structure of the form elements generated were determined. All investigations were carried out for a deep drawing steel, a 5182 aluminium alloy and an AZ31 magnesium alloy.

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Manoj Simha, C. Hari, Javad Gholipour, Alexander Bardelcik, and Michael J. Worswick. "Prediction of Necking in Tubular Hydroforming Using an Extended Stress-Based Forming Limit Curve." Journal of Engineering Materials and Technology 129, no. 1 (August 9, 2006): 36–47. http://dx.doi.org/10.1115/1.2400269.

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This paper presents an extended stress-based forming limit curve (XSFLC) that can be used to predict the onset of necking in sheet metal loaded under non-proportional load paths, as well as under three-dimensional stress states. The conventional strain-based ϵFLC is transformed into the stress-based FLC advanced by Stoughton (1999, Int. J. Mech. Sci., 42, pp. 1–27). This, in turn, is converted into the XSFLC, which is characterized by the two invariants, mean stress and equivalent stress. Assuming that the stress states at the onset of necking under plane stress loading are equivalent to those under three-dimensional loading, the XSFLC is used in conjunction with finite element computations to predict the onset of necking during tubular hydroforming. Hydroforming of straight and pre-bent tubes of EN-AW 5018 aluminum alloy and DP 600 steel are considered. Experiments carried out with these geometries and alloys are described and modeled using finite element computations. These computations, in conjunction with the XSFLC, allow quantitative predictions of necking pressures; and these predictions are found to agree to within 10% of the experimentally obtained necking pressures. The computations also provide a prediction of final failure location with remarkable accuracy. In some cases, the predictions using the XSFLC show some discrepancies when compared with the experimental results, and this paper addresses potential causes for these discrepancies. Potential improvements to the framework of the XSFLC are also discussed.

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Chao, D. Y., W. Z. Shao, J. T. Jiang, and L. Zhen. "Analysis Of Surface Orange Peel Of Automotive Aluminum Alloy Pipe Using Electron Backscatter Diffraction (EBSD)." KnE Materials Science 1, no. 1 (October 12, 2016): 24. http://dx.doi.org/10.18502/kms.v1i1.557.

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<p>The occurrence of orange peel in 6xxx alloy tube for automotive application was studied by super depth metallographic microscope and EBSD. The results revealed obvious ups and downs morphology at the surface after tube hydroforming. Compared with the undeformed case, more grains existed in the concave areas rather than individual out-of-plane displacement. The influence of surface orange peel on grain boundary morphology, crystal orientation, and texture are discussed. It is concluded, that surface orange peel is controlled by the spatial distribution of grain orientations and grain size through the thickness of the sample.</p>

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Teng, Buang, Weinian Wang, Yinquan Liu, and Shijian Yuan. "Bursting Prediction of Hydroforming Aluminium Alloy Tube based on Gurson-Tvergaard-Needleman Damage Model." Procedia Engineering 81 (2014): 2211–16. http://dx.doi.org/10.1016/j.proeng.2014.10.310.

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Journal articles on the topic 'Aluminium alloys- Hydroforming'

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