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Hydroforming

About: Hydroforming is a research topic. Over the lifetime, 2796 publications have been published within this topic receiving 26293 citations. The topic is also known as: Bulge forming.


Papers
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Journal ArticleDOI
T. S. Noh, Dong-Yol Yang1
TL;DR: In this article, a general kinematically admissible velocity field is suggested for the upper-bound solution of hydroforming of arbitrarily-shaped boxes, which is then applied to hydroforming an elliptic-circular box.
Abstract: A general kinematically admissible velocity field is suggested for the upper-bound solution of hydroforming of arbitrarily-shaped boxes. The suggested formulation is then applied to hydroforming of an elliptic-circular box. From the proposed velocity field, the fluid pressure vs. punch stroke relationship to render uniform thickness and the deformed configuration are determined by minimizing the total power consumption with respect to some chosen parameters. Experiments are carried out in the hydroforming press according to the computed pressure vs. punch stroke curve. The assumption of uniform wall thickness is confirmed by measuring the thickness variation. The effects of various process parameters including blank size, work-hardening exponent and frictional coefficient on the pressure curve are analyzed and discussed. It is thus shown that the proposed method of analysis in the present study can be effectively used for hydroforming of arbitrarily-shaped boxes.

8 citations

01 Aug 2011
TL;DR: In this article, the analysis of the sheet hydroforming with punch (SHF-P) process using finite element (FE) simulations is presented, and preliminary experiments are conducted to determine the process parameters (blank holder force versus punch stroke and pot pressure versus stroke) to form a challenging shape.
Abstract: The sheet hydroforming with punch (SHF-P) process offers great potential for low and medium volume production, especially for forming: (1) lightweight sheet materials such as aluminum (Al) and magnesium (Mg) alloys and (2) thin gage high strength steels (HSS). Mg and Al alloys are being increasingly considered for automotive applications, primarily due to their lightweight and high strength-to-weight ratios. However, there is limited experience-based knowledge of process parameter selection and tool design for SHF-P of these materials. Thus, there is a need for a fundamental understanding of the influence of process parameters on part quality. This paper summarizes analyses of the SHF-P process of AA5754-O sheet using finite element (FE) simulations. FE simulations and preliminary experiments of SHF-P were conducted to determine the process parameters (blank holder force versus punch stroke and pot pressure versus stroke) to form a challenging shape (a cylindrical cup with a reverse bulge) successfully at room and elevated temperature (~150℃). The material properties of the sheet material were obtained from tensile tests at room temperature up to 260℃ as presented by [1]. The FE model was established using PAMSTAMP 2G, Version 2009. SHF-P experiments were conducted in order to (ⅰ) evaluate the formability of the part at room and elevated temperatures and (ⅱ) validate FE simulation results. This study shows that the SHF-P at elevated temperature can form a cup with larger cup height and better reverse bulge profile than SHF-P at room temperature. Moreover, the FE predictions of part profiles and thinning distributions matched reasonably well with the experimental results.

8 citations

Patent
05 Mar 2003
TL;DR: In this article, the problem of providing a soluble lubricating surface-treated metal product for sheet hydroforming used when a metal pipe such as a steel pipe, an aluminum pipe or the like is mounted in a mold and pushed into the mold in a pipe axis direction by applying internal pressure to the pipe to be processed into a predetermined shape, and a molding processing method therefor.
Abstract: PROBLEM TO BE SOLVED: To provide a soluble lubricating surface-treated metal product for hydroforming used when a metal pipe such as a steel pipe, an aluminum pipe or the like is mounted in a mold and pushed into the mold in a pipe axis direction by applying internal pressure to the pipe to be processed into a predetermined shape or a soluble lubricating surface-treated metal product for sheet hydroforming used when a metal sheet such as a steel sheet, an aluminum sheet or the like is mounted in the mold to be processed into a predetermined shape by applying internal pressure to the sheet, and a molding processing method therefor. SOLUTION: The soluble lubricating surface-treated metal product for hydroforming excellent in moldability and emulsion-resistant hydraulic oil properties has a soluble lubricating resin film on its surface. The soluble lubricating resin film desirably contains an aqueous composition (A) of soluble polyurethane, which contains an acid group in its molecule, containing a mixture of sodium hydroxide and an amine, a mixture of potassium hydroxide and the amine or a mixture of sodium hydroxide, potassium hydroxide and the amine as a neutralizing agent of the acid group and a lubricating function imparting agent (B) added in an amount of 1-50 mass % with respect to the polyurethane composition.

8 citations

Proceedings ArticleDOI
29 Aug 2011
TL;DR: In this article, the effects of temperature and steel grade on the formability of the medium were investigated using the well known deep drawing steel DC04, and the results of the forming operations using this medium were presented.
Abstract: The need of lightweight construction for the body in white of modern cars increases due to legal restrictions of CO₂ emissions and the passenger s wishes of safety and low fuel consumption. On e approach of lightweight construction is the use of high and ultra high strength steel, to reduce the weight of the single parts, another approach is the use of modem forming technologies, e.g. hydroforming with the po ssibility to create undercuts, to produce complex parts and thus to reduce the number of parts, the number of joining operations and the weight. The mentioned ultra high strength steels show a poor formability at room temperature and the necessary process forces are high compared to standard deep drawing steels. Warm form ing operations can help to reduce the process forces and to increase form ability [1]. To combine the benefits of warm forming and hydroforming new forming media are necessary to overcome the problem of temperature stability of fluids, which is limited to about 350℃ [2]. Beside gases, which tend to leakage and which are highly compressible, granular material 1ike small ceramic beads can be used as a form ing medium. First results of forming operations using this medium were presented in [3]. The experimental tool used for those tests pressurizes the medium by a punch. To divide the effects caused by temperature and steel grade from the other effects experiments were carried out at room temperature using the well known deep drawing steel DC04. In fluences of the ceramic beads diameter, the number of repetitions, the punch geometry as the punch position, determining the volume of media, on the forming are presented.

8 citations

Journal ArticleDOI
TL;DR: In this paper, a tool concept has been developed that uses the drives of a hydraulic press with die cushion, which is used to produce the tools interior pressure and the forming pressure liquid tin as incompressible active medium.
Abstract: Lightweight design of cars is one way to reduce fuel consumption and increase the range of cars. This is an important factor to attain the EU limit values for CO2 emissions for vehicles and so to escape penalties for exceeding these limits as of the year 2012. The increasing uses of high-strength steels or of lightweight structures are adequate means to reducing weight. At IPH – Institut fur Integrierte Produktion Hannover gGmbH a method to produce hollow profiles made of aluminum was developed. The method combines flashless forging and tube hydroforming. This is called hydroforging. With this method it is possible to produce thick-walled hollow aluminum profiles with undercuts without complex tool kinematics. The forging is supported by an active medium. A tool concept has been developed that uses the drives of a hydraulic press with die cushion. With this tool various component geometries were produced and analysed. To produce the tools interior pressure and the forming pressure liquid tin as incompressible active medium was used. The forming is initiated by an upsetting of the aluminum profiles and supported by the active medium, so that the profile is pushed against the engraving of the dies. The process was designed based on simulations and verified by practical experiments. This paper describes the development of the forging process with active medium and the discussion of the forging experiment results.

8 citations


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Performance
Metrics
No. of papers in the topic in previous years
YearPapers
202330
202298
202158
202087
201981
201895