Process Parameter Correlation in Low Pressure Hydro Forming of 6063-O Aluminium Tubes

Saji Soundararaj,Kalaichelvan K,Christopher T

doi:10.5755/j01.mech.25.1.20326

Saji Soundararaj, Kalaichelvan K + Show 1 more

Open Access

https://doi.org/10.5755/j01.mech.25.1.20326

Copy DOI

Abstract

The study is performed to investigate the effects of low pressure tubular hydro-forming process parameters on the protrusion height and percentage change in wall thickness of 6063-O aluminium tubes. A mathematical correlation for these parameters are developed employing Box-Behnken response surface method. The required responses are obtained using a developed finite element model considering elastic-plastic material behaviour and validated. It is inferred that the higher friction induced on the contact surfaces of the components significantly influences the geometrical dimensions of final product. Also, it is suggested that the components require sufficient time period to undergo severe plastic deformation that can be provided by slower rate of loading during process. DOI: http://dx.doi.org/10.5755/j01.mech.25.1.20326

Highlights

The low-pressure hydro-forming process gets great attention in recent years among various automotive and aerospace industries
The quality of final product depends on various parameters and some of the important parameters are tube wall thickness, tube length, loading time and coefficient of friction
This higher plastic strain zone indicates the onset of necking in the component that leads to failure

Summary

Introduction

The low-pressure hydro-forming process gets great attention in recent years among various automotive and aerospace industries. It is carried out with constant internal pressure and axial force to form the components. The quality of final product depends on various parameters and some of the important parameters are tube wall thickness, tube length, loading time and coefficient of friction These parameters are unique when different tube component is fabricated using this process and these factors should be considered within an optimum range during fabrication. For a constant die arrangement, the outer diameter of tube remains constant and other factors namely wall thickness, tube length, internal pressure and axial force can be varied. All these variation affects the wall thinning / thickening and protrusion profile

Methods

Results

Conclusion