Quality comparison of Y-shape joints by tube hydroforming with and without counterforce
The design capability, strength, and structural rigidity provided by tube hydroforming (THF) are successfully used in many applications to produce high-strength parts and assemblies with improved mechanical properties, optimized service life, and weight features. In tubular metal forming, output parameters such as branch height, distribution of tube wall material thickness, distribution of damage factor, metal flow, effective stress, and effective strain significantly affect the quality of the product after the forming process. Therefore, this paper aims to evaluate the manufacturing quality of Y-shape joints from AISI304 material steel tube through output parameters of THF process with and without counter punch force on numerical simulation base. The Finite Element Method (FEM) has become an established feature of metal forming technology. The objective of FEM is to replace costly and elaborate experimental testing with fast, low-cost computer simulation. The simulation study uses finite element method-based virtual prototyping techniques to characterize output parameters, gain insight into strain mechanics, and predict mechanical properties of shaped components. The research results are presented clearly and unambiguously through the evaluation of 7 criteria to compare the quality of the specimens hydroformed by two surveyed cases and optimize the crucial input process parameters. And these data can be applied in experiments, more efficient product and process design, calculation, and control of input parameters avoiding costly trial and error in industrial production. The findings can help technologists optimize process parameters in the hydroforming process of products with protrusion from a tubular blank
Abbassi, F., Ahmad, F., Gulzar, S., Belhadj, T., Karrech, A., Choi, H. S. (2020). Design of T-shaped tube hydroforming using finite element and artificial neural network modeling. Journal of Mechanical Science and Technology, 34 (3), 1129–1138. doi: https://doi.org/10.1007/s12206-020-0214-4
Metal Forming Handbook (1998). Springer, 568. doi: https://doi.org/10.1007/978-3-642-58857-0
Yasui, H., Yoshihara, S., Mori, S., Tada, K., Manabe, K. (2020). Material Deformation Behavior in T-Shape Hydroforming of Metal Microtubes. Metals, 10 (2), 199. doi: 10.3390/met10020199
Duc Quang, V., Van Duy, D., Dac Trung, N. (2021). On the Formation of Protrusion and Parameters in the Tube Hydroforming. Mechanisms and Machine Science, 521–530. doi: https://doi.org/10.1007/978-3-030-91892-7_49
Bell, C., Corney, J., Zuelli, N., Savings, D. (2019). A state of the art review of hydroforming technology. International Journal of Material Forming, 13 (5), 789–828. doi: https://doi.org/10.1007/s12289-019-01507-1
Singh, H. (2003). Fundamentals of hydroforming. Society of Manufacturing Engineers, 219.
Koç, M., Altan, T. (2001). An overall review of the tube hydroforming (THF) technology. Journal of Materials Processing Technology, 108 (3), 384–393. doi: https://doi.org/10.1016/s0924-0136(00)00830-x
Manabe, K., Amino, M. (2002). Effects of process parameters and material properties on deformation process in tube hydroforming. Journal of Materials Processing Technology, 123 (2), 285–291. doi: https://doi.org/10.1016/s0924-0136(02)00094-8
Li, S., Xu, X., Zhang, W., Lin, Z. (2008). Study on the crushing and hydroforming processes of tubes in a trapezoid-sectional die. The International Journal of Advanced Manufacturing Technology, 43 (1-2), 67–77. doi: https://doi.org/10.1007/s00170-008-1702-3
Abdelkefi, A., Malécot, P., Boudeau, N., Guermazi, N., Haddar, N. (2017). On the tube hydroforming process using rectangular, trapezoidal, and trapezoid-sectional dies: modeling and experiments. The International Journal of Advanced Manufacturing Technology, 93 (5-8), 1725–1735. doi: https://doi.org/10.1007/s00170-017-0621-6
Vollertsen, F., Plancak, M. (2002). On possibilities for the determination of the coefficient of friction in hydroforming of tubes. Journal of Materials Processing Technology, 125-126, 412–420. doi: https://doi.org/10.1016/s0924-0136(02)00292-3
Tolazzi, M. (2010). Hydroforming applications in automotive: a review. International Journal of Material Forming, 3 (S1), 307–310. doi: https://doi.org/10.1007/s12289-010-0768-2
Ngaile, G., Yang, C., Kilonzo, O. (2011). Real-Time Friction Error Compensation in Tube Hydroforming Process Control. Journal of Manufacturing Science and Engineering, 133 (6). doi: https://doi.org/10.1115/1.4005430
Ahmadi, H., Zohoor, M. (2016). Investigation of the effective parameters in tube hydroforming process by using experimental and finite element method for manufacturing of tee joint products. The International Journal of Advanced Manufacturing Technology, 93 (1-4), 393–405. doi: https://doi.org/10.1007/s00170-016-9690-1
Pham, V. N. (2007). Hydrostatic forming technology. Hanoi: Bach Khoa Publishing House.
Reddy, P. V., Reddy, B. V., Ramulu, P. J. (2019). An investigation on tube hydroforming process considering the effect of frictional coefficient and corner radius. Advances in Materials and Processing Technologies, 6 (1), 84–103. doi: https://doi.org/10.1080/2374068x.2019.1707437
Ngaile, G., Gariety, M., Altan, T. (2006). Enhancing Tribological Conditions in Tube Hydroforming by Using Textured Tubes. Journal of Tribology, 128 (3), 674–676. doi: https://doi.org/10.1115/1.2197849
Asnafi, N. (1999). Analytical modelling of tube hydroforming. Thin-Walled Structures, 34 (4), 295–330. doi: https://doi.org/10.1016/s0263-8231(99)00018-x
Teng, B., Yuan, S., Chen, Z., Jin, X. (2012). Plastic damage of T-shape hydroforming. Transactions of Nonferrous Metals Society of China, 22, s294–s301. doi: https://doi.org/10.1016/s1003-6326(12)61722-1
Liu, N., Yang, H., Li, H., Yan, S. (2016). Plastic wrinkling prediction in thin-walled part forming process: A review. Chinese Journal of Aeronautics, 29 (1), 1–14. doi: https://doi.org/10.1016/j.cja.2015.09.004
DEFORM-3D Post Ver 6.1 (Service pack 1).
Jirathearanat, S., Hartl, C., Altan, T. (2004). Hydroforming of Y-shapes—product and process design using FEA simulation and experiments. Journal of Materials Processing Technology, 146 (1), 124–129. doi: https://doi.org/10.1016/s0924-0136(03)00852-5
Gale, W. F., Totemeier, T. C. (Eds.) (2004). Smithells Metals Reference Book. Butterworth-Heinemann.
Pandey, A. K., Walunj, B. S., Date, P. P. (2018). Simulation based approach for light weighting of transmission components using tube hydroforming. Procedia Manufacturing, 15, 915–922. doi: https://doi.org/10.1016/j.promfg.2018.07.405
Ktari, A., Abdelkefi, A., Guermazi, N., Malecot, P., Boudeau, N. (2021). Numerical investigation of plastic flow and residual stresses generated in hydroformed tubes. Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications, 235 (5), 1100–1111. doi: https://doi.org/10.1177/1464420721989746
Koç, M. (Ed.) (2008). Hydroforming for advanced manufacturing. Woodhead Publishing. doi: https://doi.org/10.1533/9781845694418
Schey, J. A. (1984). Tribology in Metalworking: Friction, Lubrication, and Wear. Journal of Applied Metalworking, 3 (2), 173–173. doi: https://doi.org/10.1007/bf02833697
Nielsen, C. V., Martins, P. A. F. (2021). Metal forming: Formability, Simulation, and Tool Design. Academic Press. doi: https://doi.org/10.1016/C2020-0-02428-X
Koç, M., Allen, T., Jiratheranat, S., Altan, T. (2000). The use of FEA and design of experiments to establish design guidelines for simple hydroformed parts. International Journal of Machine Tools and Manufacture, 40 (15), 2249–2266. doi: https://doi.org/10.1016/s0890-6955(00)00047-x
Copyright (c) 2022 Quang Vu Duc, Duy Dinh Van, Trung Nguyen Dac, Quang Nguyen Huu
This work is licensed under a Creative Commons Attribution 4.0 International License.
Our journal abides by the Creative Commons CC BY copyright rights and permissions for open access journals.
Authors, who are published in this journal, agree to the following conditions:
1. The authors reserve the right to authorship of the work and pass the first publication right of this work to the journal under the terms of a Creative Commons CC BY, which allows others to freely distribute the published research with the obligatory reference to the authors of the original work and the first publication of the work in this journal.
2. The authors have the right to conclude separate supplement agreements that relate to non-exclusive work distribution in the form in which it has been published by the journal (for example, to upload the work to the online storage of the journal or publish it as part of a monograph), provided that the reference to the first publication of the work in this journal is included.