A numerical process control method for circular-tube hydroforming prediction

K. I. Johnson; B. N. Nguyen; R. W. Davies; G. J. Grant; M. A. Khaleel

doi:10.1016/j.ijplas.2003.10.006

A numerical process control method for circular-tube hydroforming prediction

K. I. Johnson, B. N. Nguyen, R. W. Davies, G. J. Grant, M. A. Khaleel

Research output: Contribution to journal › Article › peer-review

37 Scopus citations

Abstract

A numerical control algorithm is described that predicts the axial end-feed and internal pressure loads to give maximum formability of circular tubes during hydroforming. The controller tracks the stresses, strains and mechanical response of the incremental finite element solution to estimate the proper axial feed (end-feed) and internal pressure increments to apply in the next increment as the tube deforms. The algorithm uses the material stress-strain curve and the deformation theory of plasticity with Hill's criterion to relate the current stress and strain increments (from the finite element model) to the next applied load increments. A controlled increment in plastic strain is prescribed for the next solution increment, and the pressure and end-feed increments are calculated to give a constant ratio of incremental axial and hoop strains. Hydroforming simulations using this method were conducted to predict the load histories for controlled expansion of 6061-T4 aluminum tubes within a conical die shape and under free hydroforming conditions. The predicted loading paths were applied in hydroforming experiments to form the conical and free-formed tube shapes. The model predictions and experimental results are compared in this paper for deformed shape, strains and the extent of forming at rupture.

Original language	English
Pages (from-to)	1111-1137
Number of pages	27
Journal	International Journal of Plasticity
Volume	20
Issue number	6
DOIs	https://doi.org/10.1016/j.ijplas.2003.10.006
State	Published - Jun 2004
Externally published	Yes

Funding

The authors would like to thank the Pacific Northwest National Laboratory's Computational Science and Engineering Initiative for funding this research. We would also like to acknowledge the contributions of Mike Dahl and Karl Mattlin who performed the hydroforming tests and Anthony Guzman who performed the optical strain measurements described in this work. This manuscript has been authored by Battelle Memorial Institute, Pacific Northwest Division, under Contract No. DE-AC06-76RL0 1830 with the US Department of Energy. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a non-exclusive, paid-up, irrevocable, world-wide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes.

Funders	Funder number
U.S. Department of Energy
Pacific Northwest National Laboratory

Keywords

Aluminum
Finite element
Hydroforming
Metal forming
Process control

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10.1016/j.ijplas.2003.10.006

Cite this

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title = "A numerical process control method for circular-tube hydroforming prediction",

abstract = "A numerical control algorithm is described that predicts the axial end-feed and internal pressure loads to give maximum formability of circular tubes during hydroforming. The controller tracks the stresses, strains and mechanical response of the incremental finite element solution to estimate the proper axial feed (end-feed) and internal pressure increments to apply in the next increment as the tube deforms. The algorithm uses the material stress-strain curve and the deformation theory of plasticity with Hill's criterion to relate the current stress and strain increments (from the finite element model) to the next applied load increments. A controlled increment in plastic strain is prescribed for the next solution increment, and the pressure and end-feed increments are calculated to give a constant ratio of incremental axial and hoop strains. Hydroforming simulations using this method were conducted to predict the load histories for controlled expansion of 6061-T4 aluminum tubes within a conical die shape and under free hydroforming conditions. The predicted loading paths were applied in hydroforming experiments to form the conical and free-formed tube shapes. The model predictions and experimental results are compared in this paper for deformed shape, strains and the extent of forming at rupture.",

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AU - Nguyen, B. N.

AU - Davies, R. W.

AU - Grant, G. J.

AU - Khaleel, M. A.

PY - 2004/6

Y1 - 2004/6

N2 - A numerical control algorithm is described that predicts the axial end-feed and internal pressure loads to give maximum formability of circular tubes during hydroforming. The controller tracks the stresses, strains and mechanical response of the incremental finite element solution to estimate the proper axial feed (end-feed) and internal pressure increments to apply in the next increment as the tube deforms. The algorithm uses the material stress-strain curve and the deformation theory of plasticity with Hill's criterion to relate the current stress and strain increments (from the finite element model) to the next applied load increments. A controlled increment in plastic strain is prescribed for the next solution increment, and the pressure and end-feed increments are calculated to give a constant ratio of incremental axial and hoop strains. Hydroforming simulations using this method were conducted to predict the load histories for controlled expansion of 6061-T4 aluminum tubes within a conical die shape and under free hydroforming conditions. The predicted loading paths were applied in hydroforming experiments to form the conical and free-formed tube shapes. The model predictions and experimental results are compared in this paper for deformed shape, strains and the extent of forming at rupture.

AB - A numerical control algorithm is described that predicts the axial end-feed and internal pressure loads to give maximum formability of circular tubes during hydroforming. The controller tracks the stresses, strains and mechanical response of the incremental finite element solution to estimate the proper axial feed (end-feed) and internal pressure increments to apply in the next increment as the tube deforms. The algorithm uses the material stress-strain curve and the deformation theory of plasticity with Hill's criterion to relate the current stress and strain increments (from the finite element model) to the next applied load increments. A controlled increment in plastic strain is prescribed for the next solution increment, and the pressure and end-feed increments are calculated to give a constant ratio of incremental axial and hoop strains. Hydroforming simulations using this method were conducted to predict the load histories for controlled expansion of 6061-T4 aluminum tubes within a conical die shape and under free hydroforming conditions. The predicted loading paths were applied in hydroforming experiments to form the conical and free-formed tube shapes. The model predictions and experimental results are compared in this paper for deformed shape, strains and the extent of forming at rupture.

KW - Aluminum

KW - Finite element

KW - Hydroforming

KW - Metal forming

KW - Process control

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A numerical process control method for circular-tube hydroforming prediction

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