A three-dimensional finite element analysis of hydrostatic bulging of an integral polyhedron into a spherical vessel

Abstract

The recently developed integral hydro-bulge forming (IHBF) process has been introduced as a novel method of manufacturing single- and multi-layered spherical pressure vessels. The process of manufacturing spherical vessels using IHBF is rather simple in application but complex in analysis. Thus far, all studies and analyses have been experimental. The interaction of welds and flat plate elements during the hydrostatic bulging process and the ensuing state of stress and large deformation constitute a complex three-dimensional metal forming process that is not understood well. In this study, a three-dimensional finite element model of the IHBF process used in manufacturing of spherical pressure vessels is developed using the ABAQUS finite element code. The results of the forming simulation and its comparison with experimental observations as well as the deformation history in the flat plate elements are presented in this paper.