A Finite Element Analysis of T-shaped Tube Hydroforming Process
Date Issued
2007
Date
2007
Author(s)
Lin, Jui-Hao
Abstract
The application of tube hydroforming technology to improve the structure property in lightweight and high strength has drawn much attention from industry. For a part with complex shape, such as T-shaped part, axial feed is usually required to provide sufficient material to the position where the expansion ratio is much higher. In the hydroforming with axial feed, an appropriate loading path of hydraulic pressure is fundamental to the process design. In the present study, an optimum loading path for hydroforming a T-shaped part is proposed based on the finite element analysis. Compared with other loading paths published in literature, which are mainly linear paths, the proposed loading path provides better performance in the hydroforming process. The effects of process parameters, such as die shape and friction condition, on the formability in hydroforming were also studied in the present study. The major process parameters that affect the formability most were identified using a regressive analysis with the help of the finite element simulations. The hydraulic pressure required to form a minimum part corner radius was investigated in the present study, and an appropriate formula that gives the relations between hydraulic pressure and corner radius was found. The effect of tube length on the formation of protrusion was examined as well using the finite element analysis. In conjunction with the studies of loading path and process parameters, a design guideline was developed. With the use of the developed design guideline, not only the protrusion in the T-shaped part can be successfully formed with an initial tube of a minimum length, but also a nearly net shaped part can be obtained. The design guideline developed in the present study provides a relevant reference for the related research and a useful tool for the hydroforming process design.
Subjects
tube hydroforming
T-shaped part
loading path
formability
regressive analysis
finite element method
Type
thesis
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