Abstract
To observe the effect of media of the internal pressure on the equivalent stress distribution in the tube, an experimental study is done by constructing a testing rig to apply the hydraulic pressure and three dies are manufactured with different bulging configurations (square, cosine, and conical). In the other part, ANSYS APDL is generated to analyze the bulging process with hydraulic and rubber (natural and industrial) media. It was found that when the media is a rubber, the stress is decreased about 9.068% in case of cosine die and 5.4439% in case of conical die and 2.8544% in case of square die. So, it can be concluded that the internal pressure in the rubber media is much better than in hydraulic media. Also, the force needed for forming the shape using rubber is higher than that of hydraulic and the force needed to form using industrial rubber is higher than of natural rubber. The thickness distribution in the tube wall in case of rubber media is better than that for hydraulic media and for the industrial rubber is better than that for natural rubber for the same dies. In case of hydraulic, the lower forming pressure is needed to bulging process compared with the rubber media since height stress in the tube metal is existed, which causes the failure. For the case of rubber, the forming pressure that was needed to bulge process is higher when compared with the hydraulic media but with less stress in tube metal and the failure in the wall is not existed with rubber media for the same pressure of hydraulic.
Highlights
Tube hydroforming is one of the cold forming operations on metal tubes, which takes it is a consideration all enough in the coming days
In case of hydraulic media, the forming pressure needed to bulging process is less when with the rubber media but with height stress in the tube metal, and that let to cause the failure, while in case of rubber media, the forming pressure that needed to bulging process is higher using the hydraulic media but with less stress in tube metal, and the failure is not existed with rubber media for the same pressure of hydraulic
It's found that the stress is decreased about 9.068% in the rubber media in case of cosine die and 5.4439% in the rubber media in case of conical die and 2.8544% in the rubber in case of square die
Summary
Tube hydroforming is one of the cold forming operations on metal tubes, which takes it is a consideration all enough in the coming days This process is carried out using a pressure (via hydraulic fluid or rubber media) in a closed tube from both sides. Hani Aziz Ameen et al.,2016[8], studied the effect of die cavity configuration on the stress distribution in tube hydroforming process with and without rubber media. In this study the effect of the dies configuration (square, cosine, and conical) and pressure (hydraulic fluid and rubber (natural and industrial)) on the bulging process with the parameters (pressure, strain, thickness, and bulging height). Three dies are manufactured with (square, cosine, and conical) configuration for bulging process that used hydraulic or rubber (natural and industrial) media.
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