Numerical Simulation and Sensitivity Analysis for Tube Hydropiercing Quality Based on Experiments

Abstract

In the present work, the ductile fracture process of hydropiercing is simulated using Rice and Tracey ductile fracture criterion by means of the user subroutine VUMAT of ABAQUS. The simulations at different loading pressures coincide well with the experiments. Based on this criterion, the processes of hydropiercing at different technical conditions are simulated with orthogonal design and the sensitivity analysis of parameters is conducted. The sensitivity analysis shows that internal pressure plays the most important role in controlling quality of the hydropierced products, namely the sheared zone length, roll-over depth and whole coefficient Y. High pressure and better lubricant are better for all the three indexes. Large punch corner radius is better for sheared zone length and Y but worse for roll-over depth. Additionally, it is found that internal pressure and punch corner radius could be intensified each other at conditions of both larger values.