One of the most important studies in tube hydroforming process is optimization of loading paths. The primary purpose of this research is to maximize formability by detecting the optimal forming parameters. The most significant settings in the prosperity of tube hydroforming process, are internal pressure and end axial feed (i.e., load path). In this paper, a finite element analysis was performed for a double-layered tube hydroforming process using the ABAQUS/Explicit software. Then, the finite element model has been verified with published experimental data. Using design of experiments (DOE) working with the Taguchi method, 32 loading paths are designed for optimization. All 32 loading paths are modelled using the finite element method in ABAQUS/Explicit and the magnitudes of bulge height and the total thickness of tubes at the branch tip are obtained in each loading path. The regression analysis is carried out to estimate the tubes formability and obtain objective functions that are bulge height and the total thickness of tubes at the protrusion peak as functions of loading parameters (internal pressure and axial feed). For solving the multi-objective optimization problem, the non-dominated sorting genetic algorithm II (NSGA-II) is utilized and the optimum results were obtained from the Pareto optimal front. Finally, the optimized loading path was applied to the finite element model and better formability (3.4% increase in the bulge height) has been achieved in the results. تفاصيل المقالة

In this article, the effect of different yield functions on prediction of forming limit curve (FLC) for aluminum sheet is studied. Due to importance of FLC in sheet metal forming, concentration on effective parameters must be considered exactly in order to have better theoretical prediction comparing experimental results. Yield function is one of the factors which are improved by adding new coefficients that follows the behaviour of material with good approximation, so applying different yield functions can change shape and level of FLCs. In this study the yield criteria which are used in determination of forming limit curves, are Hill48, Hosford, BBC2008, Soare2008, Plunkett2008 and YLD2011. The YLD2011 yield function is more appropriate than the other yield function for prediction of the FLD of aluminum alloy. The well-known Marciniak-Kuczynski (M-K) theory and voce hardening law have also been used. To verify the numerical results, the obtained results have been compared with available experimental data. تفاصيل المقالة

In this paper, Forming Limit curves (FLCs) of AA3105 aluminum alloy sheet were obtained at four different temperatures using the Nakazima test. A novel approach based on the Nakazima test was applied to fabricate the experimental setup for determining forming limit diagrams (FLDs) at elevated temperatures. First, the Nakazima-die-set was manufactured, and a thermal system was prepared for increasing sheet and die’s temperature; then AA3105 samples were tested at four different temperatures experimentally. Moreover, the ABAQUS finite element software was employed. Three different criterions including the 2nd order of derivatives for major strain, equivalent plastic strain, and thickness strain were applied to estimate the onset of localized necking. The numerical results were verified by experiment. Both the experimental and finite element method results illustrated that the level of the forming limit diagram for the aluminum sheets improved by increasing its temperature. The forming limit improvement was not equal in every strain paths. تفاصيل المقالة

In this paper, the reasons of damage water pumps parts of the air compressor cooling system were studied. To reach this goal, the works like preparing metallographic samples, evaluation of structure, investigation of mechanical properties, the alloy parts detection and chemical analysis of deposit and corrosion products collected from the parts were performed. According to studies and results obtained, alloys suggested to be used in the impeller and casing are gray cast iron with flake graphite (random distributed) and ductile iron with spherical graphite (distributed almost uniformly), respectively. Also cause damage to the pump impeller, graphitic corrosion was described. تفاصيل المقالة