Investigation of the Geometry of Rectangular Cross Section Aluminum Parts in Low Pressure Tube Hydroforming Process

2018 ◽  
Vol 71 (6) ◽  
pp. 1445-1453 ◽  
Author(s):  
Seyed Jalal Hashemi ◽  
Farzad Rahmani
Keyword(s):  
Cross Section ◽  
Rectangular Cross Section ◽  
Tube Hydroforming ◽  
Low Pressure ◽  
Pressure Tube ◽  
Hydroforming Process

Effect of Preform During Low Pressure Tube Hydroforming

2018 ◽  
Author(s):  
Ashley Trott ◽  
Chetan P. Nikhare
Keyword(s):  
Tube Hydroforming ◽  
Low Pressure ◽  
Pressure Tube ◽  
Fluid Medium ◽  
Die Geometry ◽  
Die Filling ◽  
Hydroforming Process ◽  
Plain Strain ◽  
Formed Part

Tube hydroforming is one of the manufacturing processes to produce lightweight components for automotive and aerospace industries. In this process a fluid medium is used to form a component either with high or low internal pressure. This process has gained popularity due to its many advantages such as part consolidation, quality of the formed part, and the possibility of unique shapes with indents or angles. In low-pressure tube hydroforming, the tube is marginally pressurized to a fixed volume during the closing of the die. Tube hydroforming can produce many geometric options which reduces the need for welding operations. The success of the tube hydroforming process is contingent on the ideal combination of material properties, process limitations, process sequence, and die geometry. The focus of this paper is to investigate the effect of preform on the low-pressure tube hydroforming in terms of pressure requirement, buckling and die filling. For this, a plain strain 2D model was created and hydroforming process was simulated. The tube was preformed to various widths and then hydroformed using low pressure. Two pressure conditions were simulated. The thickening of tube was observed which resulted in buckling of the tube. With higher pressure the buckling reduced but thickening of tube increased.

Deformation Mechanics of Tube in Variation of Process Sequence During Low Pressure Tube Hydroforming

2019 ◽  
Author(s):  
Chetan P. Nikhare
Keyword(s):  
Fluid Pressure ◽  
Tube Hydroforming ◽  
Low Pressure ◽  
Pressure Tube ◽  
Process Sequence ◽  
Ferrous Metals ◽  
Deformation Mechanics ◽  
Part Consolidation ◽  
Formed Part

Abstract Tube hydroforming is the successful manufacturing process to create a variety of shapes using fluid pressure. In this process, the tube was filled with the fluid and further pressurized to deform to various shapes. Tube hydroforming is categorized into three types: higher pressure, pressure sequencing and low-pressure tube hydroforming. Ferrous and non-ferrous metals are formed using these processes. Due to uniform thinning in the formed part, the parts can be lower weight and thus proven to be the technology to create lightweight parts for automotive and aerospace industries. This process has gained popularity due to its many advantages such as part consolidation, quality of the formed part and the possibility of unique shapes with indents or angles. This paper focuses on low-pressure tube hydroforming. In low-pressure tube hydroforming, during the closing of the die the tube is marginally pressurized to a fixed volume. The focus of this paper is to investigate the deformation mechanics of the tube due to variation in the process sequence during low-pressure tube hydroforming. The circular tube was formed in a square shape. The four sides of die edges were considered as individual edges and the motion of these edges will be varied to achieve the final shape. The deformation mechanics in each condition was presented and analyzed. The thickness and strain distribution were studied. The change of tube profile pattern from the start to the end of the process were presented and compared.

Die closing force in low pressure tube hydroforming

2010 ◽  
Vol 210 (15) ◽  
pp. 2238-2244 ◽  
Author(s):  
C. Nikhare ◽  
M. Weiss ◽  
P.D. Hodgson
Keyword(s):  
Tube Hydroforming ◽  
Low Pressure ◽  
Pressure Tube ◽  
Closing Force

FEA comparison of high and low pressure tube hydroforming of TRIP steel

2009 ◽  
Vol 47 (1) ◽  
pp. 146-152 ◽  
Author(s):  
C. Nikhare ◽  
M. Weiss ◽  
P.D. Hodgson
Keyword(s):  
Trip Steel ◽  
Tube Hydroforming ◽  
Low Pressure ◽  
Pressure Tube

scholarly journals Effect of internal pressure on springback during low pressure tube hydroforming

2018 ◽  
Vol 11 (6) ◽  
pp. 855-866 ◽  
Author(s):  
Guan-nan Chu ◽  
Cai-yuan Lin ◽  
Wei Li ◽  
Yan-li Lin
Keyword(s):  
Internal Pressure ◽  
Tube Hydroforming ◽  
Low Pressure ◽  
Pressure Tube

Effect of Thickness on Tube Deformation Mechanics During Low Pressure Tube Hydroforming Process Sequence Variation

2020 ◽  
Author(s):  
Chetan P. Nikhare
Keyword(s):  
Air Pollution ◽  
Fluid Pressure ◽  
Tube Hydroforming ◽  
Low Pressure ◽  
Pressure Tube ◽  
Sudden Increase ◽  
Fluid Medium ◽  
Process Sequence ◽  
Deformation Mechanics ◽  
Formed Part

Abstract A rapid increase in fuel consumption has been seen due to a sudden increase in the usage of automotive vehicles. This results in an increase in air pollution. Due to which a stricter regulation applied by the federal government to decrease air pollution. To escape from the pollution penalty innovations are been pushed. The industry has been looking at many innovative manufacturing processes like electric assisted manufacturing, single point incremental forming, high-speed forming, and many. All these innovative processes promise more uniform deformation and increases formability in the part. One such process is tube hydroforming for tubular parts. Tube hydroforming is the successful manufacturing process to create a variety of shapes using fluid pressure. The fluid medium can be water with preventive additives, oil, or viscous liquid. In this process, the tube was filled with the fluid medium and further pressurized to deform to various shapes. Tube hydroforming is categorized into three types: high pressure, pressure sequencing and low-pressure tube hydroforming. Ferrous and non-ferrous metals are formed using these processes. Due to uniform thinning in the formed part, the parts can be lower weight and thus proven to be the technology to create light-weight parts for automotive and aerospace industries to increase the fuel economy. Tube hydroforming has gained popularity due to its many advantages such as part consolidation, quality of the formed part and the possibility of unique shapes with indents or angles. This paper focuses on low-pressure tube hydroforming. In low-pressure tube hydroforming, during the closing of the die the tube is marginally pressurized to a fixed volume. The previous study which was published in IMECE2019 was focused on investigating the deformation mechanics of the tube due to variation in the process sequence during low-pressure tube hydroforming. In the second part of this research focus on how the thickness of the tube affect the deformation mechanics in the variation of the process sequence during low-pressure tube hydroforming. The circular tube was formed in a square shape. The four sides of die edges were considered as individual edges and the motion of these edges will be varied to achieve the final shape. The deformation mechanics in each condition was presented and analyzed. The relative thickness and strain distribution were studied. The change of tube profile pattern from the start to the end of the process were presented and compared. It was found that the deformation mechanics was mostly influenced by the variation of movement by punch and die side with no internal pressure case. The buckling in the tube wall also depended on which side of the die moves to deform the tube.

Buckling in low pressure tube hydroforming

2017 ◽  
Vol 28 ◽  
pp. 1-10 ◽  
Author(s):  
C. Nikhare ◽  
M. Weiss ◽  
P.D. Hodgson
Keyword(s):  
Tube Hydroforming ◽  
Low Pressure ◽  
Pressure Tube
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