IJAMS RECENT DEVELOPMENT OF HYDROFORMING-A REVIEW.

Transcription

1 IJAMS RECENT DEVELOPMENT OF HYDROFORMING-A REVIEW F. Forouhandeh 1, S. Kumar 2, S. N. Ojha 3 1 Department of Engineering, Shahrood Branch, Islamic Azad University, Shahrood, Iran fariborzforouhandeh@gmail.com 2 Department of Mechanical Engineering IIT BHU santosh.kumar.mec@itbhu.ac.in 3 Department of Metallurgical Engineering IIT BHU ojha_bhu@yahoo.co.in Abstract: Hydroforming is one of the recent forming technologies in which hollow tubes (THF) and sheet work pieces (SHF) are formed under high fluid pressure. Sheet hydroforming (SHF) process is found to be special one for different kind of sheet metal component manufacturing. Hydroforming has been a major field of interest for engineering and scientific research as well as designers, developers to look for its optimal process in terms of surface quality and part consolidation. Most of the papers reviewed herein relate to modeling and simulation of the process and the various issues such as process parameters, and experimental study of different alloys. In this paper, the review of various aspects of research on sheet and tube hydroforming process has been presented. Finally, scope of possible work that is going to be done has been introduced. Keywords: Sheet hydroforming, Tube hydroforming, Finite element method 1. Introduction Metal forming of light alloys has become very popular due to high strength to weight ratio product formation by forming processes. Automobile, Sanitary, aerospace etc are very common due to the capability of light alloys to be formed in variety of shapes by variety of forming operations. Hydroforming has become very popular forming process today to meet the challenges of these industries. Tube hydroforming [THF] and sheet hydro-forming [SHF] are relatively complex manufacturing process. The process is better than the conventional manufacturing via stamping and welding such as: (i) Part consolidation resulting in weight reduction of the component, (ii) weight reduction through more efficient section design and tailoring of the wall thickness, (iii) reduced tooling cost, (iv) improved structural strength and stiffness, (v) less number of secondary operations, (vi) reduced dimensional variation, (vii) significant reduction in spring back effects and (viii) reduced scrap rate. The analysis and performance of the process depends on many factors such as part geometry and design, material and process parameters and the boundary condition of forming. The best and easy way to study the behavior of the process for these alloys is by Finite Element method and Computer Aided Engineering based procedure. The technology of product manufacturing by THF and SHF is developing very fast to shape complex profiles of products. 2. Principles in hydroforming The working principle for sheet hydroforming is shown in figure1 as an example. After blank setting and blank holding, when the punch pushes the sheet metal into the die cavity, within which oil or other liquids are contained, high pressure that can press the sheet metal tightly onto the punch will be generated. Then, the effect of Volume 15 Issue 2 27

2 F. Forouhandeh, S. Kumar, S. N. Ojha friction retention is affected. At the same time the liquid in the die cavity will flow out between the upper surface of the die and the sheet metal. Therefore, fluid lubrication that will reduce frictional force is produced. Tube hydro-forming is a process of forming closed and hollow section of different crosssections by applying an internal hydraulic pressure in conjunction with end axial feeds. A tube is placed in the tool cavity, whereby the geometry of the die corresponds to the external geometry of the produced part (figure2). These tools, in most cases separated in longitudinal direction, are closed by the ram movement of a press, and the tube ends are loaded by two punches moving along the tube axis. Each of the loads applied to the tube ends for sealing the tube s interior must be at least equal to the force calculated from the product of the tube s internal area and the tube s internal pressure. However, the axial forces may be increased to a higher value if the forming job requires it and then the additional tube wall material is brought into the tool cavity. Internal pressure is increased during the process until the expanding tube wall comes into contact with the inner surface of the die cavity. This principle may be used for hydroforming both straight and pre-bent tubes. Screw and hydraulic presses can be used for hydroforming. They should have speed controller and displacement measurement accommodations. Figure 3 shows various hydroforming processes and its applications. Figure 4-7 shows schematic of different types of sheet hydroforming process. Table 1 shows common products for hydroforming. 3. Main review work of sheet hydroforming process There are some investigations about Sheet hydroforming like Zhang. et.al.[1] investigated a brief review of recent developments in the area of hydroforming and their relevant history with process variations for forming tubular and flat components. Applications of shell type products have also been reported in most of German aircraft. Hein.et.al.[2] carried out an investigation about hydroforming of sheet metal pairs and numerical and experimental study wherein Hydroforming of sheet metal pairs (a new class of HF) has also been investigated concerning different models, simulations and experiments on unwelded sheet metal pairs. It is found that numerical simulations and experimental study influence various parameters on the process feasibility and the result of experiments confirmed the FEM simulations results. Novontny. et.al.[3] carried out an investigation about SHF of Al-alloys (AA6016-T4) and illustrated the advantages of SHF over other alloys. It is formed that SHF of Aluminum alloy has good mechanical properties. Zhang. et.al.[4] proposed a movable die for SHF process and carried out numerical and experimental study to improved the forming characteristics of alloys. The limit drawing ratio of the sheet was improved. This process is especially suitable for forming of small batch production of sheet metal parts with complicated shapes. Zampaloni. et.al.[5] carried out numerical and experimental investigations in stamp hydroforming by using pressurized viscous fluid.(for aluminum(3003-h14-aluminum) alloy). Wherein, one or both surfaces of the sheet metal are supported with a pressurized viscous fluid to assist with stamping of the part thus (no need to female die). The pressurized fluid has several purposes: a) Supports the sheet metal from the start to the end of the forming process,thus : better deformation. b) Delays the onset of material failure. c) Reduces wrinkle formation. Experiments, shows draw depths improvements up to 31% before the material failed. Zhang. et.al.[6] has carried out a new SHF technology using a movable die comparing between THF and SHF and used a movable female die in SHF. Where in SHF technology are summarized w.r.t increase in the feeding of materials and local deformation capacity for SHF. Development of SHF technology is still much slower than THF technology. Volume 15 Issue 2 28

3 Recent Development Of Hydroforming-A Review Nielsen et.al. [7] investigated resent development of SHF for lightweight components and expressed the requirements of press control equipments. Lang et.al. [8] carried out numerical and experimental research about application of viscous pressure forming(vpf)for non-symmetric steel, aluminum and nickel parts. FEM simulation and blank holding force control was used for optimization the process conditions. It has been discussed effect of process variables upon the achievable part geometry. Comparison between FEM results and experiments illustrated simulation was used to predict material flow with high accuracy. Merklein. et.al.[9] carried out numerical and experimental study for joining tube and double sheet in hydroforming. Both of tube and sheets were formed simultaneously jointed. The finite element analysis and laboratory trials were used to design the die cavity so as to avoid the wrinkling of material tearing and the collapsibility of the tube section during forming. The analytical model of the author predicts the experiment conditions well. Abedrabbo. et.al.[10] carried out an important investigation about wrinkling behavior of Aluminum alloys during SHF. In this research FEM and experimental study have been implemented for 6111-T4 aluminum alloy. It shows that, the use of pressurized fluid delays the onset of material rupture and acts as a blank holding force to control wrinkling in the flange area. An optimum fluid pressure profile generated by FEM was applied in SHF to make the deepdrawn hemispherical cup without tearing and with minimal wrinkling in the flange area. The FEM model predicts the location of the material rupture in pure stretch and wrinkling characteristics of the Aluminum alloy sheet. Lang. et.al.[11] carried out numerical and experimental study of hydromechanical deep drawing (HDD) by using very thin middle layer in multi-sheet hydroforming. The main advantage of SHF has been to be uniform pressure transferred to everywhere. Some features on the formed forced internal, external and middle layers including high drawing ratio, wall thickness distributions, free wrinkling and fracture were also discussed. Hama. et.al.[12] carried out numerical and experimental study on elliptical deep drawing using an elastoplastic FEM (code STAMP3D) program. Where in simulated result could predict experimental result about the thickness strain distribution. The comparison between conventional process and SHF process (numerically and experimentally shows that SHF gives better formability. Murr. et.al.[13] carried out investigation about metallurgical and microstructural characterization of a hydro formed steel part. Microstructural characterization by light optical metallography (LOM) and transmission electron microscopy (TEM), (including grain structures) was carried out. Hojjati. et.al.[14] simulated super plastic forming in hydroforming process. The investigation of Aluminum alloy 5083 in hydroforming process was simulated at three different constant pressures, and effect of pressure on thickness distribution and final dome height were evaluated. Paper shows the work on Titanium alloys (Ti-6Al-4V,Ti-6Al-2Sn-4Zn- 2Mo) and Aluminum alloys (5083,7475)are typical examples of metallic super plastic materials. It is observed that Low flow stress and high sensitivity of flow stress to strain rate are the main feature of super plastic deformation. Swadesh Kumar Singh and D. Ravi Kumar et. al.[15] carried out studies to see the effect of process parameters on product surface finish and thickness variation in hydro-mechanical deep drawing. Anup K. Sharma and Dinesh K. et. al.[16] carried out Finite element analysis and experimental study on sheet Hydro mechanical forming of circular cup by using LS-DYNA. F. Forouhandeh, S. Kumar, S. N. Ojha and B. Nahak et. al.[17] fabricated setup of SHF and tested for Aluminum, Copper and Brass sheets. Advantage of sheet hydroforming process in comparison to conventional deep drawing has been illustrated using microstructure analysis. Volume 15 Issue 2 29

4 F. Forouhandeh, S. Kumar, S. N. Ojha Table 2 shows literature review of sheet hydroforming and contribution of any author in this work. 4. Main review work of Tube hydroforming process The work reported by Woo et. al.[18] incorporate experimental and analytical result for tubes bulged under internal pressure and axial compressive loading under a numerical study assuming the entire length of the bulged tube to be in tension and thus, free bulging took place. The comparison of experimental and theoretical results indicated good agreement when stress-strain properties of tubes obtained from bi-axial tests were used in calculations. Limb et. al.[19] used oil as the pressurizing medium in their experiments to investigate forming of copper, Aluminum, low carbon steel and brass Tee-shaped tubular parts. Results with different lubricants and material evaluations were reported in terms of protrusion height attainable. Sauer et. al.[20] presented the theoretical and experimental work on necking criterion of bulged tubes. Woo [21], Woo and Lua [22] described their experimental tooling and presented their theoretical analysis based on the stresses and strains taking into account the anisotropy effect of the sheet metals in separate papers. Manabe and Nishimura [23] investigated the influence of strain-hardening exponent and anisotropy on the forming of tubes in hydraulic bulging and nosing processes. They briefly presented the maximum internal pressure as a function of tube radius, thickness, strain hardening exponent, and strength coefficient assuming no axial loading. Manabe et. al.[24] worked on deformation behavior and examined the limits of forming for Aluminium tubes under both internal pressure and axial force. Axial cylinders and internal pressure were controlled by a computer-control-system to obtain predefined stress ratio during their experiments. Fuchizawa et. al.[25] analyzed the bulge forming of finite-length, thin-walled cylinders under internal pressure using incremental plasticity theory. Nader et. al.[26] used analytical models to see the limits of free forming and the influence of different material and process parameters on loading path and the corresponding forming limit result. It was also pointed on the type of experimental investigation to be carried out for hydroforming. Li-Ping Leia et. al.[27] developed a FEM program HydroFORM-3D for analyzing and designing the tube hydro formed parts for automobile rear axle housing and sub-frame. Ray and Donald [28] conducted experimental studies for X- and T- branch components for different loading paths (forming pressure and axial feed) via data acquisition system integrated with THF machine and compared the results with simulation values. There have been efforts to help industry people by developing a Computer aided process planning system (CAPPS[29,30]) for THF products. Table 3 shows most of literature review of tube hydroforming and contribution of any author in this work. Nowadays, commercially pure Titanium (CP Ti) is being paid much attention due to its properties of lightness, high specific ratio of strength to weight, strength against high temperature, antirust and good adaptability for a living body. Sheet hydroforming of CP Ti sheets is especially important for the production of thin-walled structural components used in the electronics and aerospace products, such as the cover cases of notebook and camera, mobile phone. But low ductility, high spring back and sensitivity against atmosphere elements especially Oxygen above recrystalization temperature of Titanium makes some limitations for any kind of metal forming. F. Forouhandeh, S. Kumar, S. N. Ojha and Parkash T. O. [31] carried out modeling of sheet hydroforming process for Commercially Pure Titanium grade 1for cup shape products and optimized the process in terms of defect free products. DEFORM3D package has been used for finite element simulation and parametric study. Volume 15 Issue 2 30

5 Recent Development Of Hydroforming-A Review 5. Conclusion Literature review of sheet hydroforming and tube hydroforming has been carried out. Most of the works include review of developments about SHF & THF, Numerical(FEM based analysis) and experimental study of SHF & THF process; propose of some new method such as using female die in SHF, investigations about SHF of Aluminum alloys and optimization of SHF like avoiding of tearing and wrinkling during process and avoiding of bursting and thinning during THF. But there are some challenges such as optimization of process parameters related to SHF of CP Titanium and Titanium alloys and its experimental study. Also microstructure analysis of hydroformed Titanium parts is an area which is still to be exploded in the field of sheet hydroforming process. Figure 4: Hydro mechanical deep drawing [9] Figure 1: Schematic of the sheet hydroforming process: (a) blank setting; (b) blank holding; (c) drawing and (d) finishing [9] Figure 5: Hydraulic stretch forming [8] Figure 2: Tube hydroforming: 1, tube 2, lower die 3, upper die 4, axial punch [9] Figure 6: Hydroforming using a membrane Diaphragm [8] Figure 3: Various hydroforming processes and its applications [9] Volume 15 Issue 2 31

6 F. Forouhandeh, S. Kumar, S. N. Ojha Figure 7: Double blank hydroforming [8] Table1: Common products of hydroforming Table2: Literature review of SHF Issues Review of developments Sheet hydroforming of aluminium alloys Experimental and numerical Year Author Zhang Zhang Novotny Farhang Pourboghrat Farhang Contribution review of developments Developed of SHF technology by using movable die Developed of sheet metal pairs from aluminium alloys Developed of wrinkling control of SHF of AL alloys Developed of hydroforming of sheet metal Volume 15 Issue 2 32

7 Recent Development Of Hydroforming-A Review study of SHF Comparison between SHF and THF Optimization of material flow and propose new method Microstructure Experimental study Experimental and numerical study of SHF Experimental study and microstructure analysis Pourboghrat M.Zampaloni Lihui Lang Takayuki Hama L.H.Lang M.Geiger Shi-Hong Zhang Taylan Altan Lihui Lang M.H.Hojjati L.E.Murr Swadesh Kumar Singh Anup K. Sharma F. Forouhandeh & S. Kumar pairs Developed of stamp hydroforming of sheet metals Developed of multi-layer SHF by using the very thin layer in the middle Developed of elliptical cup deep drawing by SHF Investigate of classifications and its characteristics Developed of SHF and THF for manufacturing of complex parts Developed of SHF by using a movable female die Developed of SHF by using a viscous pressure medium Developed of SHF by using a optimized model about tool dimensions and friction coefficient Developed of SHF of superplastic Investigation of metallurgical characterization of a hydroformed steel part Investigation of effect of process parameters on product surface finish Experimental and numerical study of SHF of circular cup Microstructure analysis of sheet hydroformed light alloys Numerical study and optimization 2012 F. Forouhandeh & S. Kumar Modelling of SHF process of CP Titanium Table3: Most of the literature review of THF Issues Experimental and numerical study of THF Analysis and experimental study of THF Parametric study Year Author Woo Limb Sauer Woo Manabe Li-Ping Leia Ray Contribution experimental and analytical study for tubes bulged under internal pressure Development of T branch products of Brass and Cu Theoretical and experimental work on necking criterion of bulged tubes Investigation of anisotropy effect of the sheet metals for THF Investigation of influence of strain-hardening exponent and anisotropy on the forming of tubes in hydraulic bulging Analyzing and designing the tube hydro formed parts for automobile rear axle housing Studying in T and X branch THF History presentation 1999 S.H.Zhang Recent development and history Volume 15 Issue 2 33

8 F. Forouhandeh, S. Kumar, S. N. Ojha Analysis, numerical and experimental study Computer aided process planning P.Hein Sarang & S. Kumar Sreenivasulu & S. Kumar Investigation about hydroforming of sheet metal pairs CAPP of rapid prototyping Generative CAPP for THF 6. References 1. Zhang S. H., 1999, Developments in hydroforming, Journal of Materials Processing Technology, 99, Hein P. and Vollertsen F., 1999, Hydroforming of sheet metal pairs, Journal of Materials Processing Technology, 87, Novotny S. and Hein P., 2001, Hydroforming of sheet metal pairs from aluminum alloys, Journal of Materials Processing Technology, 115(1), Zhang S. H., Zhou L. X., Wang Z. T., Xu Y., 2003, Technology of sheet hydroforming with a movable female die, International Journal of Machine Tools and Manufacture, 43, Zampaloni M., Abedrabbo N., Pourboghrat F., 2003, Experimental and numerical study of stamp hydroforming of sheet metals, International Journal of Mechanical Science, Zhang S. H., Wang Z. Xu R., Y., Wang Z. T., Zhou L. X., 2004, Recent developments in sheet hydroforming technology, Journal of Materials Processing Technology, Nielsen K. B., 2004 Hydroforming highlights:sheet hydroforming and tube hydroforming, Journal of Materials Processing Technology, 155, Lang L. H., Wang Z. R., Kang D. C., Yuan S. J., Zhang S. H., Danckert J., Ahmetoglu M., Hua J., Kulukuru S., Altan T., 2004, Hydroforming of sheet metal using a viscous pressure medium, Journal of Materials Processing Technology, 146, Merklein M., Geiger M., Celeghini M., 2005, Combined tube and double sheet hydroforming for the manufacturing of complex parts, Journal of Manufacturing Technology, 54, Abedrabbo N., Zampaloni M. A., Pourboghrat F., 2005, Wrinkling control in aluminum sheet hydroforming, International Journal of Mechanical Science, 43, Lang L., Danckert J., Nielsen K. B., 2005, Multi-layer sheet hydroforming: Experimental and numerical investigation into the very thin layer in the middle, Journal of Materials Processing Technology, 170, Hama T., Hatakeyama T., Asakawa M., 2007, Finite element simulation of the elliptical cup deep drawing process by sheet hydroforming, finite elements in analysis and design, Journal of Material Characterization, 43, Murr L. E., Gayton S. M., Lopez M. I., Bujanda D. E., 2008, Metallurgical characterization of a hydroformed, 304 tainless steel, Caribbean-style musicalpan, Journal of Material Characterization, 59, Hojjati M. H., Zoorabadi M., Hosseinpour S. J., 2008, Optimization of superplastic hydroforming process of Aluminum alloy Volume 15 Issue 2 34

9 Recent Development Of Hydroforming-A Review 5083, Journal of Materials Processing Technology, 205, Kumar Singh S. and Ravi Kumar D., 2008, Effect of process parameters on product surface finish and thickness variation in hydro-mechanical deep drawing, Journal of Materials Processing Technology, 204, Anup K. Sharma, Dinesh K, 2009, Finite element analysis of sheet Hydromechanical forming of circular cup, Journal of Materials Processing Technology, 209, Forouhandeh F., Kumar S., Ojha S. N., Nahak B., 2012, Development of a Sheet Hydro forming setup and product characterization, 4 th International and 25 th All India Manufacturing Technology, Design and Research Conference, (AIMTDR), 2, Woo D. M., 1973, Tube-Bulging under Internal Pressure and Axial Force, Journal of Materials Processing Technology, 95, Limb M. E., Chakraborty J., Garber S., Roberts W. T., 1976, Hydraulic Forming of Tubes, Sheet Metal Industries, Sauer W. J., Gotera A., Robb F., Huang P., 1978, Free Bulge Forming of Tubes under Internal Pressure and Axial Compression, Proceeding of the Sixth NAMRC, Woo D.M., 1978, Development of a bulge forming process, Sheet Metal Industries, Woo D.M., 1978, Lua A., Plastic deformation of anisotropic tubes in hydraulic bulging, Journal of Materials Processing Technology, 100, Manabe K. and Nishimura H., 1983 Influence of material properties in forming of tubes, Bander Bleche Rohre, Manabe K., Mori S., Suzuki K. and Nishimura H., 1984, Bulge forming of thin-walled tubes by micro-computer controlled hydraulic press, Advance Technology Plasticity, 1, Fuchizawa S., 1984, Influence of strain hardening exponent on the deformation of thin-walled tube of finite length subjected to hydrostatic external pressure, Advance Technology Plasticity, 1, Asnafi N., 1999, Analytical modeling of tube hydroforming, Journal of Thin-Walled Structures, 34, Leia Li-Ping, Kima Dae-Hwan, Kangb Sung-Jong, Hwanga Sang-Moon, Kang Beom-Soo, 2001 Analysis and design of hydroforming processes by the rigid plastic finite element method, Journal of Materials Processing Technology, 114, Ray P. and Mac Donald B.J., 2005, Experimental study and finite element analysis of simple X- and T-branch tube hydroforming processes, International Journal of Mechanical Sciences, 47, Sarang S. Pande and Kumar S., 2008, A Generative process planning system for parts produced by Rapid prototyping, International journal of Production Research, 46(22), Sreenivasulu B., 2007, Analysis and Simulation of Hydroforming Process Unpublished M.Tech. Thesis, IT-BHU Varanasi INDIA), Forouhandeh F., Kumar S., Ojha S. N., Parkash T. O., 2012, Modeling of Sheet Hydroforming of CP Titanium for semispherical cup shape product, International Journal of Modeling and Simulation in Design and Manufacturing (JMSDM),3, Volume 15 Issue 2 35

10 F. Forouhandeh, S. Kumar, S. N. Ojha Biography Fariborz Forouhandeh is Ph.D. Scholar in Department of Mechanical Engineering IIT BHU, also a faculty member (lecturer) in department of engineering, Islamic Azad University, Shahrood branch, Iran. He has Master degree in Mechanical engineering, production and manufacturing from University of Science and Technology of Iran. Santosh Kumar is Professor in Department of Mechanical Engineering IIT BHU. He has Ph.D. degree from IIT Kanpur. He is a fellow of Institution of Engineers (India). He is working in area of manufacturing. S. N. Ojha is Professor in Department of Metallurgical Engineering IIT BHU. He is program coordinator in this department. He is a fellow of Indian Institute of Metals, Institution of Engineers and Life Member, in Materials Research Society of India. Volume 15 Issue 2 36