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TECHNICAL PAPERS

Analysis of Tube Free Hydroforming Using an Inverse Approach With FLD-Based Adjustment of Process Parameters

[+] Author and Article Information
Ba Nghiep Nguyen, Kenneth I. Johnson, Mohammad A. Khaleel

Computational Mechanics and Material Behavior Group, Pacific Northwest National Laboratory, Richland, WA 99352

J. Eng. Mater. Technol 125(2), 133-140 (Apr 04, 2003) (8 pages) doi:10.1115/1.1555651 History: Received February 25, 2002; Revised August 12, 2002; Online April 04, 2003
Copyright © 2003 by ASME
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References

Asnafi,  N., 1999, “Analytical Modeling of Tube Hydroforming,” Thin-Walled Struct., 34, pp. 295–330.
Asnafi,  N., and Skogsgärdh,  A., 2000, “Theoretical and Experimental Analysis of Stroke-Controlled Tube Hydroforming,” Mater. Sci. Eng., A, A279, pp. 95–110.
Chenot, J. L., Wood, R. D., and Zienkiewicz, O. C., eds, 1992, “Numerical Methods in Industrial Forming Processes,” NUMIFORM 92. A. A. Balkema, Rotterdam, Netherlands.
Owen, D. R. J., Onate, E., and Hinton, E., eds, 1997, “Computational Plasticity—Fundamentals and Applications,” COMPLAS V, CIMNE, Barcelona, Spain.
Guo,  Y. Q., Batoz,  J. L., Detraux,  J. M., and Duroux,  P., 1990, “Finite Element Procedures for Strain Estimations of Sheet Metal Forming Parts,” Int. J. Numer. Methods Eng., 30, pp. 1385–1401.
Guo,  Y. Q., Batoz,  J. L., Naceur,  H., Bouabdallah,  S., Mercier,  F., and Barlet,  O., 2000, “Recent Developments on The Analysis and Optimum Design of Sheet Metal Forming Parts Using a Simplified Inverse Approach,” Comput. Struct., 78, pp. 133–148.
Batoz,  J. L., Guo,  Y. Q., and Mercier,  F., 1998, “The Inverse Approach with Simple Triangular Shell Elements for Large Strain Predictions of Sheet Metal Forming Parts,” Eng. Comput., 15(7), pp. 864–892.
Chung,  K., Barlat,  F., Brem,  J. C., Lege,  D. J., and Richmond,  O., 1997, “Blank Shape Design for a Planar Anisotropic Sheet Based on Ideal Forming Design Theory and FEM Analysis,” Int. J. Mech. Sci., 39, pp. 105–120.
Chung,  K., Yoon,  J.-W., and Richmond,  O., 2000, “Ideal Sheet Forming with Frictional Constraints,” Int. J. Plast. 16, pp. 595–610.
Lee,  C. H., and Huh,  H., 1998, “Blank Design and Strain Estimates for Sheet Metal Forming Processes by A Finite Element Inverse Approach with Initial Guess of Linear Deformation,” J. Mater. Process. Technol., 82, pp. 145–155.
Yoon, J.-W., Chung, K., Pourboghrat, F., Barlat, F., and Shah, K. N., 2002, “Preform Design for Hydroforming of Extruded Parts Based on Ideal Forming Design Theory,” Plasticity, Damage and Fracture at Macro, Micro and Nano Scales, Proceedings of Plasticity 02, A. S. Khan and O. Lopez-Pamies, eds., NEAT Press, Maryland, pp. 460–462.
Nguyen, B. N., Johnson, K. I., Davies, R. W., and Khaleel, M. A., 2002, “Inverse Analysis of Tube Free Hydroforming,” Plasticity, Damage and Fracture at Macro, Micro and Nano Scales, Proceedings of Plasticity 02, A. S. Khan and O. Lopez-Pamies, eds., NEAT Press, Maryland, pp. 427–429.
Nguyen, B. N., Johnson, K. I., Davies, R. W., and Khaleel, M. A., 2002, “A Computation Tool for Hydroforming Prediction Using an Inverse Approach,” SAE Technical Paper Series, Paper # 2002-01-0785, SAE 2002 World Congress, Detroit, Michigan, March 2002.
Hill,  R., 1948, “A Theory of The Yielding and Plastic Flow of Anisotropic Metals,” Proc. R. Soc. London, Ser. A, A193, pp. 281–297.
Lemaitre, J., and Chaboche, J. L., 1985, Mécanique des Matériaux Solides, Bordas, Paris.

Figures

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Principle of tube free hydroforming
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Schematics of stable shapes during free hydroforming
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Loading paths: end-feed versus internal pressure for a hot-dip galvanized (HG/Z140) DP600 tube (L0=220 mm,2R0=60 mm,h0=1.47 mm). The figure also shows the analytical and experimental curves used in 2.
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Triangular finite element mesh and deformed configuration (for s1=s2=4.2 mm) of a quarter of the tube
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Equivalent plastic strains for the deformed configuration illustrated in Fig. 4: (a) incremental analysis (b) inverse analysis
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Equivalent plastic strains along a longitudinal arc length measured from a tube end to a middle section point
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Equivalent stresses for the deformed configuration illustrated in Fig. 4: (a) incremental analysis (b) inverse analysis
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Distribution of external forces per unit area for the deformed configuration illustrated in Fig. 4. The values in the unsupported section correspond to the internal pressure intensity.
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Thickness distributions for the deformed configuration illustrated in Fig. 4: (a) incremental analysis (b) inverse analysis
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Thickness distributions along a longitudinal arc length considered in Fig. 6
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Prediction of failure based on the forming limit diagram: (a) FLD-based criterion according to Eq. (14), (b) snapshot of the failure area (colored in white).
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Initial mesh determined by the inverse analysis
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FLD-based criterion values after end-feed adjustments. The new end-feed value is s1=s2=7.35 mm.
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Prediction of internal pressure in the deformed tube after end-feed adjustments
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Equivalent plastic strains after end-feed adjustments
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Thickness distribution after end-feed adjustments
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Thickness distributions along a longitudinal arc length measured from the beginning of the unsupported portion to the middle section of the tube: (a) before end-feed adjustment (b) after end-feed adjustment

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