Advertisement

A new method for hydroforming of thin-walled spherical parts using overlapping tubular blanks

  • 59 Accesses

Abstract

Tube hydroforming is an advanced metal forming processes, which is widely used to form various tubular parts. Axial feeding is usually used to avoid excessive thinning in hydroforming of a variable-diameter part. However, wrinkling defects are susceptible to occur easily under the axial loading if the wall thickness of the tube is small. A new method was proposed to enhance the expansion ratio and improve the thickness distribution for hydroforming of thin-walled spherical parts using overlapping tubular blanks. A special loading tool was created and AISI 304 stainless steel blanks were used for the experimental research. The effects of blank shapes and normal constraints were studied on wrinkling defects of the overlapping blanks. The results show that wrinkling defects at the inner layer of the overlap are prevented by using curved-edge blanks. Wrinkling defects at the outer layer of the overlap is eliminated by using normal constraints. Finally, a sound thin-walled spherical part was obtained by using an overlapping tubular blank. The maximum expansion ratio is 60% and increased by 30.2% compared with that of conventional hydroforming using a closed cross-sections tube. The maximum thinning ratio was 32.4%, which was decreased by 29.3%. In general, it is feasible to use an overlapping blank to form a variable diameter part. The maximum expansion enhances significantly and the thickness distribution improves apparently.

This is a preview of subscription content, log in to check access.

Access options

Buy single article

Instant unlimited access to the full article PDF.

US$ 39.95

Price includes VAT for USA

Subscribe to journal

Immediate online access to all issues from 2019. Subscription will auto renew annually.

US$ 199

This is the net price. Taxes to be calculated in checkout.

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16

References

  1. 1.

    Koç M, Altan T (2001) An overall review of the tube hydroforming (THF) technology. J Mater Process Technol 108(3):384–393

  2. 2.

    Yuan SJ, Han C, Wang XS (2006) Hydroforming of automotive structural components with rectangular-sections. Int J Mach Tools and Manuf 46(11):1201–1206

  3. 3.

    Xie WC, Han C, Chu GN, Yuan SJ (2015) Research on hydro-pressing process of closed section tubular parts. Int J Adv Manuf Technol 80(5–8):1149–1157

  4. 4.

    Alaswad A, Benyounis KY, Olabi AG (2012) Tube hydroforming process: a reference guide. Mater Des 33:328–339

  5. 5.

    Carleer B, Kevie GVD, Winter LD, Veldhuizen BV (2000) Analysis of the effect of material properties on the hydroforming process of tubes. J Mater Process Technol 104(1):158–166

  6. 6.

    Manabe KI, Amino M (2002) Effects of process parameters and material properties on deformation process in tube hydroforming. J Mater Process Technol 123(2):285–291

  7. 7.

    Plancak M, Vollertsen F, Woitschig J (2005) Analysis, finite element simulation, and experimental investigation of friction in tube hydroforming. J Mater Process Technol 170:220–228

  8. 8.

    Ngaile G, Jaeger S, Altan T (2004) Lubrication in tube hydroforming (THF): part I. lubrication mechanisms and development of model tests to evaluate lubricants and die coatings in the transition and expansion zones. J Mater Process Technol 146(1):108–115

  9. 9.

    Abdelkefi A, Malécot P, Boudeau N, Guermazi N, Haddar N (2017) Evaluation of the friction coefficient in tube hydroforming with the “corner filling test” in a square section die. Int J Adv Manuf Technol 88:2265–2273

  10. 10.

    Kang BH, Lee MY, Shon SM, Moon YH (2007) Forming various shapes of tubular bellows using a single-step hydroforming process. J Mater Process Technol 194(1–3):1–6

  11. 11.

    Shin SGR, Joo BD, Tyne CJV, Moon YH (2014) Enhancing tube hydroformability by reducing the local strain gradient at potential necking sites. J Mech Sci Technol 28(10):4057–4062

  12. 12.

    Zhang Q, Wu CD, Zhao SD (2012) Less loading tube-hydroforming technology on eccentric shaft part by using movable die. Mater Trans 53(5):820–825

  13. 13.

    Wada M, Mizumura M, Iguchi K, Kaneda H (2014) Large-expansion hydroforming technology achieving three-times expanding. 11th Int Conf Technol Plast (ICTP). Nagoya 81:2217–2222

  14. 14.

    Varma NSP, Narasimhan R (2008) A numerical study of the effect of loading conditions on tubular hydroforming. J Mater Process Technol 196(1–3):174–183

  15. 15.

    Han C, Liu Q, Lu H, Gao GL, Xie WC, Yuan SJ (2018) Thickness improvement in hydroforming of a variable diameter tubular component by using wrinkles and preforms. Int J Adv Manuf Technol 99(9–12):2993–3003

  16. 16.

    Imaninejad M, Subhash G, Loukus A (2005) Loading path optimization of tube hydroforming process. Int J Mach Tools and Manuf 45(12–13):1504–1514

  17. 17.

    Ben Abdessalem A, El-Hami (2014) A global sensitivity analysis and multi-objective optimization of loading path in tube hydroforming process based on metamodelling techniques. Int J Adv Manuf Technol 71(5–8):753–773

  18. 18.

    An H, Green DE, Johrendt J (2012) A hybrid-constrained MOGA and local search method to optimize the load path for tube hydroforming. Int J Adv Manuf Technol 60(9–12):1017–1030

  19. 19.

    Paquette JA, Kyriakides S (2006) Plastic buckling of tubes under axial compression and internal pressure. Int J Mech Sci 48(8):855–867

  20. 20.

    Koç M, Altan T (2002) Prediction of forming limits and parameter in the tube hydroforming process. Int J Mach Tools and Manuf 42(1):123–138

  21. 21.

    Daxin E, Mizuno T, Li ZG (2008) Stress analysis of rectangular cup drawing. J Mater Process Technol 205(1–3):469–476

  22. 22.

    S CZ, C GL, L ZQ (2005) Determining the optimum variable blank-holder forces using adaptive response surface methodology (ARSM). Int J Adv Manuf Technol 26(1–2):23–29

Download references

Author information

Correspondence to Cong Han.

Ethics declarations

Competing interests

The authors declare that they have no competing interests.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and Permissions

About this article

Verify currency and authenticity via CrossMark

Cite this article

Han, C., Feng, H. A new method for hydroforming of thin-walled spherical parts using overlapping tubular blanks. Int J Adv Manuf Technol 106, 1543–1552 (2020) doi:10.1007/s00170-019-04743-6

Download citation

Keywords

  • Hydroforming
  • Overlapping blank
  • Thin-walled
  • Wrinkling
  • Thickness