Hot Hydroforming of Sheets and Tubes : An Overview€¦ · • Hot hydroforming is needed for...
Transcript of Hot Hydroforming of Sheets and Tubes : An Overview€¦ · • Hot hydroforming is needed for...
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Hot Hydroforming of Sheets and Tubes : An Overview
Prof. P. P. DateDepartment of Mechanical Engineering IIT Bombay
Powai, Mumbai 400076
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Disclaimer• The entire presentation is based on published
literature. The source of information has been indicated at the bottom of each slide.
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Why Hot Hydroforming ?• High strength alloys – High YS at room temperature
– Greater frictional force (due to greater forming force)– Nonuniform strain distribution– Need to deform under hot conditions – Usual working media like oil & water good until 300 deg C
• Three questions : – Means of heating the workpiece to a high working temperature– Working media that will work under high temperatures– Pressurising working media at high working temperatures
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Working Media & MaterialsWorking Media• Granular medium• Hot Gas Methods of heating• Resistance heating• Furnace heatingMaterials• Titanium alloys• Hot forming steels for autobody components
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Issues in hot hydroforming• Heating of workpiece by heaters embedded in the dies • Die heating too slow due to large energy requirement• Hot gas hydroforming : Temperature distribution complex• Process (formability) is sensitive to temperature • In service properties are sensitive to temperature• Uniform temperature distribution for a circular tube• Larger circumferential temperature variation for a rectangular tube• Microstructure evolves during forming. Processing maps are
important to establish manufacturing parameters
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Processing steps in hot hydroforming
Source : T. Maeno, K-I Mori, K. Fujimoto, Manufacturing Rev. 1(2014)5
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A possible manufacturing setup
Compressed air in the sealed tube
Min. hydroforming pressure at temperature Ta1
Source : T. Maeno, K-I Mori, K. Fujimoto, Manufacturing Rev. 1(2014)5
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Power : 60 kW; 10V & 6000AElectrode (Cu) width : 35mmContact area = 32900 mm2
To prevent overheating : water cooled electrodes by demineralised water at 18 deg C
Electrical insulation : PEEK cylindrical elements (between tube and machine frame)
Source : F. Michieletto, A. Ghiotti, S. Bruschi, Key Engg. Materials, 611-612(2014)62-69
Alloy AA6060 Chemical composition
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Source : F. Michieletto, A. Ghiotti, S. Bruschi, Key Engg. Materials, 611-612(2014)62-69
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Electrical and Thermal parameters
Source : F. Michieletto, A. Ghiotti, S. Bruschi, Key Engg. Materials, 611-612(2014)62-69
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High temperature behaviour of Al 6063 alloy
The Al alloy has practically ZERO strain rate sensitivity
Source : T. Maeno, K-I Mori, K. Fujimoto, Manufacturing Rev. 1(2014)5
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Mechanical Behaviour of AA 6060 alloy
Shows small strain rate sensitivitySource : F. Michieletto, A. Ghiotti, S. Bruschi, Key Engg. Materials, 611-612(2014)62-69
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Free Bulging
Source : T. Maeno, K-I Mori, K. Fujimoto, Manufacturing Rev. 1(2014)5
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What may go wrongTube melted out due to overheating Tube melted out due to overheating
NO axial feeding
Failure due to tensile stresses in hoop & axial directions
Source : T. Maeno, K-I Mori, K. Fujimoto, Manufacturing Rev. 1(2014)5
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Expansion ratio
P0 = 0.8 MPa
J = 76 A/mm2
Source : T. Maeno, K-I Mori, K. Fujimoto, Manufacturing Rev. 1(2014)5
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More Uniform temperature distribution
Source : T. Maeno, K-I Mori, K. Fujimoto, Manufacturing Rev. 1(2014)5
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Axial feed + temperature
Source : T. Maeno, K-I Mori, K. Fujimoto, Manufacturing Rev. 1(2014)5
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Pulsating pressure in hydroforming
M. Loh Mousavi, M. Bakhshi-Jooyabari, K-I Mori, K. Hayashi, Inst Mech. Engg Part B, J. Engg. Mfg 222(2008)1139-1146
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Thickness distribution
M. Loh Mousavi, M. Bakhshi-Jooyabari, K-I Mori, K. Hayashi, Inst Mech. Engg Part B, J. Engg. Mfg 222(2008)1139-1146
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Amplitude and Frequency of PulsationΔp = 7 MPa ω = 0.33
cycles/mm of stroke
Δp = 7 MPa
M. Loh Mousavi, M. Bakhshi-Jooyabari, K-I Mori, K. Hayashi, Inst Mech. Engg Part B, J. Engg. Mfg 222(2008)1139-1146
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High Pressure Pneumatic Forming
• Material : Ti-3Al-2.5V alloy• Strain rate sensitive alloy• Adopting the lower pressurization rate and
filling regenerative materials into the tube are effective methods for decreasing or eliminating the temperature difference.
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Pressurisation and Corner filling
G. Liu. J. Wang, K. Dang, S. Yuan, Int. J. Adv. Manuf. Technol. 85(2016)869-879
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Tensile behaviour
Ductility in Uniaxial tension
G. Liu. J. Wang, K. Dang, S. Yuan, Int. J. Adv. Manuf. Technol. 85(2016)869-879
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Corner filling
T = 700 deg C
G. Liu. J. Wang, K. Dang, S. Yuan, Int. J. Adv. Manuf. Technol. 85(2016)869-879
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Other means of Hydroforming
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Granular medium based hydroforming
H. Chen et. Al., CIRP Annals, Manufacturing Technology, 65(2016)273-276
Hot formed Without working medium
Hot formed With working medium
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Formability in hot hydroforming
H. Chen et. Al., CIRP Annals, Manufacturing Technology, 65(2016)273-276
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Hot Hydroforming Stainless Steel• Ferritic stainless steels • Better corrosion resistance (esp. SCC)• Lower coeff. Of thermal expansion• High thermal conductivity• Poor formability in warm working; better above 700 deg C• Quartz / Zirconia beads are safe forming media• Inherent friction between granules and tube aids axial
feeding
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Hot forming stainless steel & Media
H. Chen, D. Staupendahl, L. Hiegemann, A. E. Tekkaya, Proc. IDDRG2017 Conf., Munich 2017
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Tube OD = 50mm, wall thk = 1.5mmH. Chen, D. Staupendahl, L. Hiegemann, A. E. Tekkaya, Proc. IDDRG2017 Conf., Munich 2017
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Forming limits & Fracture Limits
Forming Limit
Fracture Limit
H. Chen, D. Staupendahl, L. Hiegemann, A. E. Tekkaya, Proc. IDDRG2017 Conf., Munich 2017
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Forming with hot granular media
H. Chen, D. Staupendahl, L. Hiegemann, A. E. Tekkaya, Proc. IDDRG2017 Conf., Munich 2017
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In Summary• Hot hydroforming is needed for sheets & tubes of high
temperature materials• The working medium depends upon the temperature
capability of each. • Hot gas forming, granular media are viable options• Gas and granular media have their own advantages in
hot forming• Pulsating pressure works better than monotonic
pressure of the working fluid / media
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Thank you