Abstract
The warm tube hydroforming (WTHF) process of lightweight materials such as magnesium alloy contributes to a remarkable weight reduction. The success of the WTHF process strongly depends on the loading path with internal pressure and axial feeding and other process variables including temperature distribution. Optimization of these process parameters in this special forming technique is a great issue to be resolved. In this study, the optimization of the symmetrical temperature distribution and process loading path for the warm T-shape forming of magnesium alloy AZ31B tube was carried out by finite element (FE) analysis using a fuzzy model. As a result, a satisfactory good agreement of the wall thickness distribution of the samples formed under the optimum loading path condition can be obtained between the FE analysis result and the experimental result. Based on the validity validation of FE analysis model, the optimization method was applied to other materials and forming shapes, and applicability was discussed.
Highlights
Field for Magnesium Alloy Tubes.In recent years, the world has begun to move toward carbon neutrality as one of the solutions to prevent global warming
In order to clarify the process window in warm T-shape forming of AZ31B magnesium alloy and the Finite element (FE) modeling validation, warm tube hydroforming (WTHF) experiments and FE analysis were performed in a proportional loading path under a uniform temperature field
Under experimental constraints w forming time of 5 min at 250 C or below, optimization of temperature distribution and forming time of min at or below, optimization of temperature distributio loading path during process using fuzzy inference model previously developed by the loading path during process using fuzzy inference model previously developed b authors was attempted
Summary
Field for Magnesium Alloy Tubes.In recent years, the world has begun to move toward carbon neutrality as one of the solutions to prevent global warming. Tube hydroforming (THF), which uses a tubular material with a hollow cross section for high rigidity, is considered to be promising for reducing the weight of vehicles, in addition to material replacement with lightweight materials and high-strength materials, and is applied in the automotive industry. Magnesium, and fiber-reinforced polymers have been taken up as typical lightweight materials. Magnesium is the lightest of all practical metals and is attracting attention as one of the important metals for realizing a low-carbon society due to its unique physical and mechanical properties. Magnesium alloys have been treated as one of the hard-to-form metals at room temperature. Several metal forming processes for magnesium alloys using a heat-assisted approach have been introduced in order to enhance the formability and reduce the environmental load
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