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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
01 Sep 2017
TL;DR: The content of this paper deals with the development of a finite element simulation model for the free-bending process with 6 degrees of freedom, able to reproduce complex deflection curves in combination with innovative low-thickness material design for hydroforming processes.
Abstract: High-strength steel and aluminum alloys are essential for developing innovative, lightly-weighted space frame concepts. The intended design is built from car body parts with high geometrical complexity and reduced material-thickness. Over the past few years, many complex car body parts have been produced using hydroforming. To increase the accuracy of hydroforming in relation to prospective car concepts, the virtual manufacturing of forming becomes more important. As a part of process digitalization, it is necessary to develop a simulation model for the hydroforming process chain. The preforming of longitudinal welded tubes is therefore implemented by the use of three-dimensional free-bending. This technique is able to reproduce complex deflection curves in combination with innovative low-thickness material design for hydroforming processes. As a first step to the complete process simulation, the content of this paper deals with the development of a finite element simulation model for the free-bending process with 6 degrees of freedom. A mandrel built from spherical segments connected by a steel rope is located inside of the tube to prevent geometrical instability. Critical parameters for the result of the bending process are therefore evaluated and optimized. The simulation model is verified by surface measurements of a two-dimensional bending test.

17 citations

Journal ArticleDOI
TL;DR: In this paper, a tube hydroforming of aluminum alloy (AA1050) at various temperatures has been investigated numerically to study temperature effect on thickness distribution of final product and a warm hydroforming set-up has been designed and manufactured to evaluate numerical results.
Abstract: Reduction of weight and increase of corrosion resistance are among the advantageous applications of aluminum alloys in automotive industry. Producing complicated components with several parts as a uniform part not only increases their strength but also decreases the production sequences and costs. However, achieving this purpose requires sufficient formability of the material. Tube hydroforming is an alternative process to produce complex products. In this process, the higher the material formability the more uniform will be the thickness distribution. In this research, tube hydroforming of aluminum alloy (AA1050) at various temperatures has been investigated numerically to study temperature effect on thickness distribution of final product. Also a warm hydroforming set-up has been designed and manufactured to evaluate numerical results. According to numerical and experimental results in the case of free bulging, unlike the constrained bulging, increase of the process temperature causes more uniform thickness distribution and therefore increases the material formability.

17 citations

Journal ArticleDOI
TL;DR: The response surface methodology along with the finite element method was employed to optimize the loading path for hydroforming parallel double branched tube parts and the optimized result was in good agreement with the experimental results.

17 citations

Patent
21 Oct 2003
TL;DR: In this article, a threaded hole is formed in a hydroformed part with a single tool while the part remains in the hydroforming die cavity, and an annular region of the part extending about the hole is extruded inwardly to form an integral tubular neck defining a hole of predetermined depth.
Abstract: Method and apparatus are disclosed wherein a required threaded hole is formed in a hydroformed part with a single tool while the part remains in a hydroforming die cavity. In forming the threaded hole, a hole is first pierced in the wall of the part and then an annular region of the part extending about the hole is extruded inwardly to form an integral tubular neck defining a hole of predetermined depth. The hole is then expanded in a sizing operation to a diameter determined by the required thread to be formed therein by material displacement and the required thread is then formed in the wall of the hole in a material displacing manner.

17 citations

Journal ArticleDOI
TL;DR: In this paper, a finite element method (FEM) program for the design of preforms in tube hydroforming, which utilizes a rigid-plastic approach and the backward tracing scheme, is constructed with careful numerical treatment of boundary conditions at the die-workpiece interface.

17 citations


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