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Journal of Engineering Materials and Technology | Volume 132 | Issue 3 | Research Paper
Research Papers

Tube Hydroforming of Magnesium Alloys at Elevated Temperatures

[+] Author and Article Information
Yeong-Maw Hwang1

Department of Mechanical and Electro-Mechanical Engineering, National Sun Yat-Sen University, Kaohsiung 804, Taiwanymhwang@mail.nsysu.edu.tw

Yan-Huang Su, Bing-Jian Chen

Department of Mechanical and Electro-Mechanical Engineering, National Sun Yat-Sen University, Kaohsiung 804, Taiwan

1

Corresponding author.

J. Eng. Mater. Technol 132(3), 031012 (Jun 24, 2010) (11 pages) doi:10.1115/1.4001833 History: Received September 02, 2008; Revised April 29, 2010; Published June 24, 2010; Online June 24, 2010
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Citing Articles

In this paper, a hydraulic forming machine with the functions of axial feeding, counter punch, and internal pressurization is designed and developed. This self-designed forming machine has a capacity of 50 tons for axial feeding and counter punch, 70 MPa for internal pressurization, and 300°C for forming temperature. Using this testing machine, experiments of T-shape protrusion of magnesium alloy AZ61 tubes at elevated temperatures are carried out. A commercial finite element code DEFORM 3D is used to simulate the plastic deformation of the tube within the die during the T-shape protrusion process. Different kinds of loading paths for the pressurization profile and the strokes of the axial feeding and the counterpunch are scheduled for analyses and experiments of protrusion processes at 150°C and 250°C. The numerical thickness distributions and the flow line configurations of the formed product are compared with the experimental results to validate this finite element modeling. The thickness distribution of the formed product or the flowability of AZ61 tubes at 150°C and 250°C is discussed. The effects of the forming rate on tube flowability at 250°C are also investigated. Through the observation of the flow line configurations of the tube material, adequate backward speeds of the counter punch relative to the axial feeding for preventing the material from accumulating at the die entrance region are verified. Finally, a sound product with a protrusion height of 49 mm is obtained.
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References

1
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Tsukeda, T., 2007, “Thixomolding Technology of Magnesium Alloy,” J. Jpn. Soc. Technol. Plast., 48 , pp. 396–400.
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Kamado, S., 2007, “Materials Properties and Working Processing of Magnesium Alloy,” J. Jpn. Soc. Technol. Plast., 48 , pp. 358–366.
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Thiruvarudchelvan, S., Seet, G. L., and Ang, H. E., 1996, “Computer-Monitored Hydraulic Bulging of Tubes,” J. Mater. Process. Technol., 57 , pp. 182–188.  [CrossRef]
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Ahmed, M., and Hashmi, M. S. J., 1997, “Estimation of Machine Parameters for Hydraulic Bulge Forming of Tubular Components,” J. Mater. Process. Technol., 64 , pp. 9–23.  [CrossRef]
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Mizukoshi, H., Okada, H., and Wakabayashi, H., 1998, “Tee Fitting Hydraulic Formability of Aluminum Alloy Tubes,” Proceedings of the 49th Japan Joint Conference on Technology Plasticity , pp. 323–324.
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Fuchizawa, S., Takano, T., Shirayori, A., and Narazaki, M., 2000, “T- and Cross-Forming of Aluminum Alloy Tubes by Internal Hydraulic Pressure and Axial Feeding,” Proceedings of the 51st Japan Joint Conference Technology Plasticity , pp. 357–358.
8
Hwang, Y. M., Lin, T. C., and Chang, W. C., 2007, “Experiments on T-Shape Hydroforming With Counter Punch,” J. Mater. Process. Technol., 192–193 , pp. 243–248.  [CrossRef]
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Koç, M., Allen, T., Jiratheranat, S., and Altan, T., 2000, “The Use of FEA and Design of Experiments to Establish Design Guidelines for Simple Hydroformed Parts,” Int. J. Mach. Tools Manuf., 40 , pp. 2249–2266.  [CrossRef]
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Aue-U-Lan, Y., Ngaile, G., and Altan, T., 2004, “Optimizing Tube Hydroforming Using Process Simulation and Experimental Verification,” J. Mater. Process. Technol., 146 , pp. 137–143.  [CrossRef]
11
Ray, P., and MacDonald, B. J., 2004, “Determination of the Optimal Load Path for Tube Hydroforming Processes Using a Fuzzy Load Control Algorithm and Finite Element Analysis,” Finite Elem. Anal. Design, 41 , pp. 173–192.  [CrossRef]
12
Manabe, K., Miyamoto, S., and Koyama, H., 2002, “Process Control of Tube Hydroforming With Fuzzy Inference,” Proceedings of the H14 Japan Spring Conference on Technology Plasticity , pp. 259–260.
13
Hwang, Y. M., Chen, B. H., and Chang, W. C., 2007, “Adaptive Simulations of T-Shape Tube Hydroforming Processes,” Key Eng. Mater., 340–341 , pp. 627–632.  [CrossRef]
14
Yuan, S., Qi, J., and He, Z., 2006, “An experimental Investigation Into the Formability of Hydroforming 5A02 Al-Tubes at Elevated Temperature,” J. Mater. Process. Technol., 177 , pp. 680–683.  [CrossRef]
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Keigler, M., Bauer, H., Harrison, D., and Silva, A., 2005, “Enhancing the Formability of Aluminum Components via Temperature Controlled Hydroforming,” J. Mater. Process. Technol., 167 , pp. 363–370.  [CrossRef]
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Okamoto, A., Naoi, H., and Kuwahara, Y., 2007, “Study on Hot Bulge Forming for Tees of Magnesium Alloy Pipe Joints,” Proceedings of the International Conference on Tube Hydroforming , pp. 121–128.
17
Neugebauer, R., Sterzing, A., Kurka, P., and Seifert, M., 2005, “The Potential and Application Limits of Temperature-Supported Hydroforming of Magnesium Alloys,” "Advances in Technology Plasticity", Proceedings of the Eighth International Conference on Technology Plasticity , pp. 293–298.
18
Kuwabara, T., and Takada, K., 2007, “Hydraulic Bulging Test of Magnesium Alloy Tube at Warm Temperature,” Proceedings of the 58th Japan Joint Conference on Technology Plasticity , pp. 249–250.
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Hwang, Y. M., and Lin, Y. K., 2007, “Evaluation of Flow Stresses of Tubular Materials Considering Anisotropic Effects by Hydraulic Bulge Tests,” ASME J. Eng. Mater. Technol., 129 , pp. 414–421.  [CrossRef]
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Kobayashi, S., Oh, S. I., and Altan, T., 1989, "Metal Forming and the Finite Element Method", Oxford University Press, New York.
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Yang, J. B., Jeon, B. H., and Oh, S. I., 2001, “Design Sensitivity Analysis and Optimization of the Hydroforming Process,” J. Mater. Process. Technol., 113 , pp. 666–672.  [CrossRef]
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Strano, M., Jirathearanat, S., Shr, S. G., and Altan, T., 2004, “Virtual Process Development in Tube Hydroforming,” J. Mater. Process. Technol., 146 , pp. 130–136.  [CrossRef]
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Jirathearanat, S., Hartl, C., and Altan, T., 2004, “Hydroforming of Y-Shapes—Product and Process Design Using FEA Simulation and Experiments,” J. Mater. Process. Technol., 146 , pp. 124–129.  [CrossRef]

Figures

Grahic Jump Location
+Schematic diagram of the platform and the tooling set: (a) top view and (b) front view
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Schematic diagram of the platform and the tooling set: (a) top view and (b) front view
Figure 1

Schematic diagram of the platform and the tooling set: (a) top view and (b) front view

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+Relationship between the tube and punches
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Relationship between the tube and punches
Figure 2

Relationship between the tube and punches

Grahic Jump Location
+Appearance of the warm hydraulic test machine
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Appearance of the warm hydraulic test machine
Figure 3

Appearance of the warm hydraulic test machine

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+Flow stresses used in the finite element simulations. (a) Stress-strain curves from tensile tests. (b) Actual flow stress input in the FEA.
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Flow stresses used in the finite element simulations. (a) Stress-strain curves from tensile tests. (b) Actual flow stress input in the FEA.
Figure 4

Flow stresses used in the finite element simulations. (a) Stress-strain curves from tensile tests. (b) Actual flow stress input in the FEA.

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+Mesh configurations of the tube before and after protrusion: (a) before forming and (b) after forming
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Mesh configurations of the tube before and after protrusion: (a) before forming and (b) after forming
Figure 5

Mesh configurations of the tube before and after protrusion: (a) before forming and (b) after forming

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+Loading path 1 and the formed product at 150°C: (a) loading path 1 and (b) appearance of the product
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Loading path 1 and the formed product at 150°C: (a) loading path 1 and (b) appearance of the product
Figure 6

Loading path 1 and the formed product at 150°C: (a) loading path 1 and (b) appearance of the product

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+Loading path 2 and the formed product at 150°C: (a) loading path 2 and (b) appearance of the product
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Loading path 2 and the formed product at 150°C: (a) loading path 2 and (b) appearance of the product
Figure 7

Loading path 2 and the formed product at 150°C: (a) loading path 2 and (b) appearance of the product

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+Thickness distribution of the product using loading path 2 at 150°C. (a) Thickness distribution at the upper portion. (b) Thickness distribution at the lower portion. (c) Longitudinal section view of the product.
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Thickness distribution of the product using loading path 2 at 150°C. (a) Thickness distribution at the upper portion. (b) Thickness distribution at the lower portion. (c) Longitudinal section view of the product.
Figure 8

Thickness distribution of the product using loading path 2 at 150°C. (a) Thickness distribution at the upper portion. (b) Thickness distribution at the lower portion. (c) Longitudinal section view of the product.

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+Loading paths used in T-shape protrusion experiments at 250°C: (a) loading path 1 and (b) loading path 2
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Loading paths used in T-shape protrusion experiments at 250°C: (a) loading path 1 and (b) loading path 2
Figure 9

Loading paths used in T-shape protrusion experiments at 250°C: (a) loading path 1 and (b) loading path 2

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+Experimental results of T-shape protrusion at 250°C. (a) Appearance of the products. (b) Thickness distributions of the products.
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Experimental results of T-shape protrusion at 250°C. (a) Appearance of the products. (b) Thickness distributions of the products.
Figure 10

Experimental results of T-shape protrusion at 250°C. (a) Appearance of the products. (b) Thickness distributions of the products.

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+Numerical and experimental results of T-shape protrusion at 250°C. (a) Thickness distribution at the upper portion. (b) Thickness distribution at the lower portion. (c) Longitudinal section view of the product.
View Large  |  Save Figure  |  Download Slide (.ppt)
Numerical and experimental results of T-shape protrusion at 250°C. (a) Thickness distribution at the upper portion. (b) Thickness distribution at the lower portion. (c) Longitudinal section view of the product.
Figure 11

Numerical and experimental results of T-shape protrusion at 250°C. (a) Thickness distribution at the upper portion. (b) Thickness distribution at the lower portion. (c) Longitudinal section view of the product.

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+Loading path 3 and the formed product at 250°C. (a) Loading path 3. (b) Thickness distribution at the upper portion. (c) Thickness distribution at the lower portion. (d) Longitudinal section view of the product.
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Loading path 3 and the formed product at 250°C. (a) Loading path 3. (b) Thickness distribution at the upper portion. (c) Thickness distribution at the lower portion. (d) Longitudinal section view of the product.
Figure 12

Loading path 3 and the formed product at 250°C. (a) Loading path 3. (b) Thickness distribution at the upper portion. (c) Thickness distribution at the lower portion. (d) Longitudinal section view of the product.

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+Loading path 4 and the formed product at 250°C. (a) Loading path 4. (b) Appearance of the formed product.
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Loading path 4 and the formed product at 250°C. (a) Loading path 4. (b) Appearance of the formed product.
Figure 13

Loading path 4 and the formed product at 250°C. (a) Loading path 4. (b) Appearance of the formed product.

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+Flow line configurations of the tube material at different instances at 250°C using loading path 4. (a) When the counterpunch is ready to move. (b) When the counterpunch moved back 20 mm. (c) Completion of the forming process.
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Flow line configurations of the tube material at different instances at 250°C using loading path 4. (a) When the counterpunch is ready to move. (b) When the counterpunch moved back 20 mm. (c) Completion of the forming process.
Figure 14

Flow line configurations of the tube material at different instances at 250°C using loading path 4. (a) When the counterpunch is ready to move. (b) When the counterpunch moved back 20 mm. (c) Completion of the forming process.

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