Abstract
Rectangular section parts created through hydroforming have good application prospects in the automotive industry because of their advantages of simple manufacturing procedure, high forming quality, and greater bending module than circular cross-sectional parts. Forming quality is directly influenced by the formed corner parameters of rectangular section parts. It is also a difficult matter in rectangular section hydroforming. The hydroforming rules of an aluminum alloy circular tube are regarded as the research object in this study to investigate the rules of square cross-sectional parts in the hydroforming process. First, the mechanical parameters of the molding material are obtained through experiments. Second, a hydroforming experimental system is self-designed, and tube hydroforming without axial feed is investigated to determine the key parameters of tube forming. Simulation analysis is then conducted for the entire process of tube hydroforming using the nonlinear finite element software DYNAFORM. The finite element model and the correctness of the calculation method are verified by comparing their results with the experimental results. Thereafter, the influence of internal pressure, friction coefficient, and loading path on pipe forming quality is examined. Necessary references are provided for engineering applications.
Highlights
With the rapid development of the aviation and automobile industries, more and more people are beginning to focus on reducing structural weight to reduce energy consumption.[1]
The results indicate that inverse finite element method (IFEM) can be used as a quick tool to estimate process parameters in tube hydroforming
Owing to the internal pressure, the friction coefficient and the load path exert a significant effect on the quality of hydroforming
Summary
With the rapid development of the aviation and automobile industries, more and more people are beginning to focus on reducing structural weight to reduce energy consumption.[1]. When the internal pressure exceeds 40 MPa, the test result of tube bulging remains unchanged, indicating that the tube completed contact with the die at the pressure of 40 MPa. The fillet radius of the rectangular cross-sectional die is R = 6 mm. To study the thickness distribution of the hydroformed tube at an internal pressure of 45 MPa, 13 measurement points were selected in a quarter of the rectangular cross-section as the research object. Experimental results are basically consistent; the maximum error is 5.56%, thereby proving that the finite element model, material experimental tests, and numerical simulation analysis are correct
Sign-in/Register to view highlights & summary Sign-in/Register to access full text options 
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a callDisclaimer: All third-party content on this website/platform is and will remain the property of their respective owners and is provided on "as is" basis without any warranties, express or implied. Use of third-party content does not indicate any affiliation, sponsorship with or endorsement by them. Any references to third-party content is to identify the corresponding services and shall be considered fair use under The CopyrightLaw.
