Forming limit diagrams of tubes with initial wall-thickness difference based on different instability criteria

Abstract

The Forming limit diagram (FLD), also known as a forming limit curves (FLC), is generally used in metal forming for predicting forming behavior of metals. The purpose of the study is to clarify the difference among the FLC of tubes with initial wall-thickness difference under tension-compression strain states using finite element (FE) simulation of tube hydroforming (THF) and different instability criteria. Firstly, geometrical models for SUS304 stainless steel tubes with initial wall-thickness differences were built by introducing an index ‘wall-thickness deviation rate’. Secondly, forced-end hydro-bugling of the tubes was modeled and the forming process was simulated by using the commercial finite element (FE) code ABAQUS/Explicit 6.10. Afterwards, the limiting strains of the material in the hydro-bugling process were calculated based on the simulated resultant data and three instability criteria--strain change criterion, strain rate change criterion and strain path change criterion, respectively. Finally, the FLD for the tubes was established and the effect of wall-thickness deviation rate on the FLD was analyzed and the differences among the FLC based on the three instability criteria were compared. The results showed that the FLC are observed to shift in the major–minor strain coordinate system due to the initial non-uniform wall-thickness; however, no distinct differences among the FLC based on the three instability criteria were observed.