Investigation of the Effect of Different Forming Pressure Curves on Formability of AA1050 Tubes in Warm Hydroforming Process
الموضوعات :
Seyed Jalal Hashemi
1
(Department of Mechanical Engineering, Faculty of Enghelab-e Eslami, Tehran Branch, Technical and Vocational University (TVU), Tehran, Iran)
الکلمات المفتاحية: Aluminum alloy, Warm Tube Hydroforming, Finite Eelement Method (FEM),
ملخص المقالة :
Reduction of weight and increase of corrosion resistance are among the advantages of applications of aluminum alloys in the automotive industry. Low formability at room temperature is the major problem in the forming of these alloys. This problem is due to alloy elements that limit the number of slip planes at room temperature. Forming at a high temperature can improve the formability of metals. In this paper, the warm hydroforming of AA1050 aluminum tubes has been studied numerically. A warm tube hydroforming setup was designed and fabricated. Aluminum tubes were formed at high temperatures. Numerical simulation of process is performed using MSC. Marc commercial software and thickness distribution were studied at various temperatures. Results showed that increasing temperature leads to a much better thickness distribution. The pressure curves which were obtained using available equations for forming at room temperature have been modified to decrease thinning in the final part. Simulations were performed in two states which are called constrained bulge and free bulge. To produce a part without any wrinkling and also to obtain minimum thinning, an axial feeding curve is suggested.
[1] Keigler, M., Bauer, H., Harrison, D., Anjali K. and De Silva, M. 2005. Enhancing the formability of aluminium components via temperature controlled hydroforming. Journal of Materials Processing Technology. 167: 363–370.
[2] Yuan, S., Qi, J. and He, Z. 2006. An experimental investigation into the formability of hydroforming 5A02 Al-tubes at elevated temperature. Journal of Materials Processing Technology. 177: 680–683.
[3] Kim, B. J., Van Tyne, C. J., Lee, M. Y. and Moon, Y. H2007. Finite element analysis and experimental confirmation of warm hydroforming process for aluminum alloy. Journal of Materials Processing Technology. 187–188: 296–299.
[4] Yi, H. K., Pavlina, E. J., Van Tyne, C. J. and Moon, Y. H. 2008. Application of a combined heating system for the warm hydroforming of lightweight alloy tubes. Journal of Materials Processing Technology. 203: 532–536.
[5] Hashemi, S. J., Moslemi Naeini, H., Liaghat, G. H., Azizi Tafti, R. and Rahmani, F. 2013. Numerical and Experimental Investigation of Temperature Effect on Thickness Distribution in Warm Hydroforming of Aluminum Tubes. Journal of Materials Engineering and Performance. 22: 57-63.
[5] Koc M. and Altan T. 2002. Prediction of forming limits and parameters in the tube Hydroforming process. International Journal of Machine Tools & Manufacture. 42: 123–138.
[6] Seyedkashi, S.M.H., Naeini, H.M. and Moon, Y.H. 2014. Feasibility study on optimized process conditions in warm tube hydroforming. Journal of Mechenical Sciences Technology. 28: 2845–2852.
[7] Hashemi, S.J., Moslemi Naeini, H., Liaghat, G.H. and Azizi Tafti, R. 2015. Prediction of bulge height in warm hydroforming of aluminum tubes using ductile fracture criteria. Archives of Civil and Mechanical Engineering. 15: 19-29.
[8] Taheri Ahangar, A., Bakhshi-Jooybari, M., Hosseinipour, S. and Gorji, H. 2019. Improvement of Die Corner Filling of Stepped Tubes Using Warm Hybrid Forming. International Journal of Engineering. 32(4): 587-595.
[9] Reddy, P.V., Reddy, B.V. and Ramulu, P.J. 2020. Effect of heat treatment temperatures on formability of SS 304 during tube hydroforming process. SN Applied Sciences. 2(2):1-12.
[10] Zhang, C., Liu, W., Huang, L., Wang, C., Huang, H., Lin, L. and Wang, P. 2021. Process analysis of biconvex tube hydroforming based on loading path optimization by response surface method. The International Journal of Advanced Manufacturing Technology. 112: 2609-2622.
[11] Taheri Ahangar, A., Bakhshi Jooybari, M., Hosseinipour, S. and Gorji, H. 2018. Experimental study and finite element simulation for determining the forming window of 6063-O aluminum tube in warm hydroforming process. Amirkabir Journal of Mechanical Engineering. 52: 571-586.
[12] Nasrollahzade, M., Moslemi Naeini, H., Hashemi, S.J., Abbaszadeh, B. and Shahbazi Karami, J. 2016. Experimental investigation of Aluminum tubes hot gas forming and production of square cross-section specimens. Modares Mechanical Engineering. 15: 435-442.
