Numerical and Experimental Study of Residual Stress Measurement and Thickness Distribution of T-shape Steel Tube Produced by Tube Hydroforming
محورهای موضوعی : Manufacturing process monitoring and controlJavad Shahbazi Karami 1 , Gholamhasan Payganeh 2 , Mohsen Khodsetan 3
1 - Faculty of Mechanical Engineering, Shahid Rajaee Teacher Training University, Tehran, Iran
2 - Faculty of Mechanical Engineering, Shahid Rajaee Teacher Training University, Tehran, Iran
3 - School of Mechanical Engineering, College of Engineering, University of Tehran, Tehran, Iran
کلید واژه: Finite Element, Residual stress, T-shaped Tube Hydroforming, Hole Drilling,
چکیده مقاله :
Tube hydroforming (THF) process is used to produce the complex components from the initial cylindrical tubes. In this paper, T- shape component was formed using a tube hydroforming machine and the residual stresses of hydroformed tube was determined by hole drilling method. Subsequently, the thickness distribution and residual stresses of final tube were investigated using experimental and finite element (FE) methods. The results represented the top of the protrusion has the minimum thickness, whereas the maximum thickness appears in the bottom zone of T-shape tube. The FE results showed that the maximum principal stress in the middle part of piece has own maximum value while the maximum value of minimum principal stress is located in the top of protrusion and the fillet transition region of the protrusion. It is found that the value of residual stress, protrusion height and thickness distribution in simulated results were in good agreement with the experimental results.
[1] Islam, M. D., Olabi, A. G. and Hashmi, M. S. J. 2006. Feasibility of multi-layered tubular components forming by hydroforming and finite element simulation. Journal of Materials processing technology, 174, 394-398.
[2] Devereaux Anthony, P., Gray John, E. and Parker William, M. 1940. Apparatus for making wrought metal t's, ed: Google Patents.
[3] Limb, M., Chakrabarty, J., Garber, S. and Mellor, P. 1973. The forming of axisymmetric and asymmetric components from tube. In Proceedings of the 14th International MTDR Conference.
[4] Woo, D. M. 1964. The analysis of axisymmetric forming of sheet metal and the hydrostatic bulging process. International Journal of Mechanical Sciences, 6, 303-317.
[5] Thiruvarudchelvan, S. 1994. A theory for the bulging of aluminium tubes using a urethane rod. Journal of materials processing technology, 41, 311-330.
[6] Powell, G. and Avitzur, B. 1973. Forming of tubes by Hydraulic Pressure. In Proceedings of the North American Metalworking Research Conference.
[7] Ueda,T. and Ogura, T. 1968 .Liquid bulge forming.Metalworking Prod, 24, 73-81.
[8] Koç, M. and Altan, T. 2001 .An overall review of the tube hydroforming (THF) technology. Journal of Materials Processing Technology, 108, 384-393.
[9] Hwang, Y. M., Lin, T. C. and Chang, W. C. 2007 .Experiments on T-shape hydroforming with counter punch. Journal of Materials Processing Technology, 192, 243-248.
[10] Hwang, Y. M. and Lin, Y. K. 2002 .FE-simulations of T-shape tube hydroforming. ed: Trans Tech Publ, 233, 317-322.
[11] Crapps, J., Marin, E. B., Horstemeyer, M. F., Yassar, R. and Wang, P. T. 2010 .Internal state variable plasticity-damage modeling of the copper tee-shaped tube hydroforming process. Journal of Materials Processing Technology, 210, 1726-1737.
[12] Manabe, K.-i., Suetake, M., Koyama, H. and Yang, M. 2006. Hydroforming process optimization of aluminum alloy tube using intelligent control technique. International Journal of Machine Tools and Manufacture, 46, 1207-1211.
[13] Loh-Mousavi, M., Bakhshi-Jooybari, M., Mori, K. I. and Hyashi, K. 2008 .Improvement of formability in T-shape hydroforming of tubes by pulsating pressure.Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 222,1139-1146.
[14] Ray, P. and Mac Donald, B. J. 2005 .Experimental study and finite element analysis of simple X-and T-branch tube hydroforming processes.International Journal of Mechanical Sciences,47,1498-1518.
[15] Prime, M. B. 1999. Residual stress measurement by successive extension of a slot: the crack compliance method. Applied Mechanics Reviews, 52, 75-96.
[16] Beaney, E. M. 1976. Accurate measurement of residual stress on any steel using the centre hole method. Strain, 12, 99-106.
[17] Chen, J., Peng, Y. and Zhao, S. 2009. Comparison between grating rosette and strain gage rosette in hole-drilling combined systems. Optics and Lasers in Engineering, 47, 935-940.
[18] Prime, M. B. 1997. Residual stress measurement by successive extension of a slot: a literature review. Los Alamos National Lab., NM (United States).
[19] Astm, E. 2008. Standard Test Method for Determining Residual Stresses by the Hole Drilling Strain Gage method. ed: ASTM Intrenational Conshohocken, PA.
[20] Giri, A., Pandey, C., Mahapatra, M. M., Sharma, K. and Singh, P. K. 2015.On the estimation of error in measuring the residual stress by strain gauge rosette.Measurement, 65, 41-49.
[21] Totten, G., Howes, M. and Inoue, T. 2002. Handbook of residual stress and deformation of steel: ASM International. Materials Park, Ohio.
