Abstract
A focus on the effect of friction condition on tube hydroforming during corner filling in a square section die is proposed. Three approaches have been developed: an analytical model from the literature has been programmed, finite element simulations have been conducted and experiments have been carried out. Effect of friction coefficient on the thickness distribution in the square section of the hydroformed tube is studied. Critical thinning is found to take place in the transition zone between the straight wall and the corner radius and this minimal thickness seems to be the more appropriate parameter for the evaluation of the friction coefficient.
Highlights
Nowadays, industries spend a lot of effort to meet new environmental standards and become more competitive
The minimum thickness obtained in the hydroformed part is plotted against the corresponding internal pressure in Fig. 8 where numerical results obtained with FE simulations and the Orban-Hu model, for two different values for the friction coefficient, are compared with the measures done on the real hydroformed part
The paper has proposed the study of friction effect and thinning during tube hydroforming in a square die with the analytical model developed by Orban and Hu, numerical simulations with LSDYNA/Explicit software and experiments
Summary
Industries spend a lot of effort to meet new environmental standards and become more competitive. Reserved for manufacturing high-tech components in the field of aerospace, hydroforming is increasingly used for aeronautical and automotive applications to meet these new economic constraints This process provides some advantages, for example: weight reduction, part consolidation, lower tooling cost, improved structural strength and stiffness, avoided secondary operations and reduced scrap [1]. The test of tube expansion test in a square die has been modelled by Orban and Hu [9] It takes the form of a semi-analytical problem that could present an interesting tool for the characterization of the Coulomb's friction coefficient, under conditions close to real tube hydroforming process. Concluding remarks and perspectives are reported in the last section
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