Finite Element and Experimental Investigation of the Multipoint Flexible Hydroforming

Abstract

FINITE ELEMENT AND EXPERIMENTAL INVESTIGATIONS OF THE MULTI-POINT FLEXIBLE HYDOFORMING. N. Selmi*, H. BelHadjSalah* *Mechanical Engineering Laboratory (LGM), National Engineering School of Monastir (ENIM), University of Monastir, Avenue Ibn El Jazzar 5019, Monastir, Tunisia. naselmi2002@yahoo.fr, hedi.belhadjsalah@enim.rnu.tn. ABSTRACT Multi-point flexible forming (MPF) process is relatively recent flexible techniques [1], instead of the conventional fixed shape die sets, the basic idea in this process, consist to form the sheet metal between a pair of opposed matrices of punch elements, by adjusting the height of the punch elements [2]. Production of many parts with different geometry will be possible, just by using one same device and the need to design and manufacturing of various dies will be avoided that lead to great saving in time and manufacturing cost specially in the field of small batch or single production. The hydroforming process is attractive compared with conventional solid die forming processes, the basic idea consist to suppress one tool of two forming tools (punch or die), which is replaced by hydraulic pressure, only one tool is necessary to define the final shape of formed sheet. The multipoint flexible hydroforming, proposed in this paper, is an original process which combines the hydroforming and the multipoint flexible forming [3], to obtain a synergy of the advantages of both processes. The new process, subject of this work, is a combination of the last described processes that keep the whole flexibility of the basic multipoint flexible forming (with two dies), by using, only at one side, a single multipoint die to perform completely the final part shape, the fluid pressure is applied on the other side of the sheet metal part and substitutes advantageously the second die. Firstly, investigations were carried out by numerical simulation, to quantify, the effect of the most influent parameters on the process performances, and to highlight the ability of this new process, in the production of complex forms, as well as its contribution in quality, placed with regards existing flexible processes. Secondly, to prove the feasibility and to carry out a valuable experimental investigation of the multipoint flexible hydroforming, an experimental prototype was designed and realized, and successful doubly curved shell shape parts were obtained by the new process testing set up. The part profiles and the thickness distribution were in agreement with those obtained by numerical investigation furthermore, numerical investigation for efficient methods to suppress the dimpling phenomenon and edge buckling were confirmed by experimental investigation. From investigations it appears that the parameters attached to the discreet character of the multipoint tool, have an important effect on the quality of the final metal sheet product, such as, the punch elements density, the punch elements extremity curvature radius, the blank and the elastomeric interpolator thicknesses. From simulation results, it emerges essentially, that an adequate setting of parameters can upgrade the thickness distribution, reduce the residual stress and attenuate the dimples.