Abstract
Hydro-joining is composed of hydro-piercing, hole flanging and nut-inlaying processes. In this study, a new hydro-flanging process combining hydro-piercing and hydro-flanging is proposed. An internal pressured fluid is used as the supporting medium instead of a rigid die. Three kinds of punch head shapes are designed to explore the thickness distribution of the flanged tube and the fluid leakage effects between the punch head and the flanged tube in the hydro-flanging process. A finite element code DEFORM 3D is used to simulate the tube material deformation behavior and to investigate the formability of the hydro-flanging processes of aluminum alloy tubes. The effects of various forming parameters, such as punch shapes, internal pressure, die hole diameter, etc., on the hydro-flanged tube thickness distributions are discussed. Hydro-flanging experiments are also carried out. The die hole radius is designed to make the maximum internal forming pressure needed smaller than 70 MPa, so that a general hydraulic power unit can be used to implement the proposed hole flanging experiments. The flanged thickness distributions are compared with simulation results to verify the validity of the proposed models and the designed punch head shapes.
Highlights
Hydro-joining is composed of hydro-piercing, hole flanging and nut-inlaying processes
The results showed that the geometrical dimensions of the roll-over depth, straight-ring zone height and thickness distributions varied with punch shapes
Hwang et al [11] used finite element simulations and experiments to investigate the effects of punch shape and various parameters such as punch strokes, internal pressures, etc., on the pierced hole surface characteristics in a tube hydro-piercing process of SPFC590Y carbon steel tubes
Summary
Energy saving and carbon dioxide reduction have become important issues in the world, especially in aerospace and transportation fields. Choi et al [9] analyzed the tube deformation behavior surrounding a hole produced by a hydropiercing process They investigated both experimentally and analytically the relationship between the deformation radius and the roll-over under different punch diameters and internal pressures. Hwang et al [11] used finite element simulations and experiments to investigate the effects of punch shape and various parameters such as punch strokes, internal pressures, etc., on the pierced hole surface characteristics in a tube hydro-piercing process of SPFC590Y carbon steel tubes. Kumar et al [15] used finite element simulations and experiments to investigate the effect of punch head profiles on deformation behavior of AA5052 alloy sheet in stretch-flanging processes. The effects of punch geometries, die hole radius and internal pressure on the formability of the hydro-flanging process and the tube thickness distributions at the ring zone after hydro-flanging are discussed. The forming conditions for obtaining sound product with a ring zone over 3 mm thick and without oil leakage at the interface between the tube and punch are explored
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