Tubular Hydroforming

VARIABLES INFLUENCING TUBULAR HYDROFORMING


03-06-2005VARIABLES INFLUENCING TUBULAR HYDROFORMING*IntroductionTube hydrofoming is extremely utilized in automotive industry.Tube hydrofoming has cutting edge over other forming operations.Tube hydrofoming produces excellent result in the manufacturing of hollow cross-section bodies.By optimizing the process parameters suitably very good results can be achieved .


03-06-2005VARIABLES INFLUENCING TUBULAR HYDROFORMING*Process descriptionPress closed and holding pressure appliedSEAL PUNCHTOP PUNCH HALFBOTTOM DIE HALFCOUNTER PUNCHSCHEMATIC VIEW OF EXPERIMENTAL SETUP


03-06-2005VARIABLES INFLUENCING TUBULAR HYDROFORMING*Process descriptionEnd feed appliedSECONDARY CONTOURSCHEMATIC VIEW OF EXPERIMENTAL SETUP


03-06-2005VARIABLES INFLUENCING TUBULAR HYDROFORMING*Process descriptionOpening press and ejecting componentT-JOINTSCHEMATIC VIEW OF EXPERIMENTAL SETUP


03-06-2005VARIABLES INFLUENCING TUBULAR HYDROFORMING*Blank shapes


03-06-2005VARIABLES INFLUENCING TUBULAR HYDROFORMING*Preforms


03-06-2005VARIABLES INFLUENCING TUBULAR HYDROFORMING*Types of tube hydroformingTUBE HYDROFORMINGFREE HYDROFORMINGTOOL DEPENDENT HYDROFOMING


03-06-2005VARIABLES INFLUENCING TUBULAR HYDROFORMING*Die layout


03-06-2005VARIABLES INFLUENCING TUBULAR HYDROFORMING*Tube properties affecting HydroformingPredicting behavior of formability is difficult.The effect of tube on hydroforming is expressed bycorner radiuslubricationend feed


03-06-2005VARIABLES INFLUENCING TUBULAR HYDROFORMING*Tube properties affecting HydroformingTest specimen:size: O.D.= 76.2mmmaterial:AKDQ(HR) -2.0mmAKDQ(HR) -2.5mmHSLA -2.0mmIF galvannel -2.0mmIF galvanized-2.0mmDP600 -2.0mmlubricant:dry film lubricant (water-borne emulsion)/(0.04-0.05)wet lubricant (mill oil 61-aus)/(0.15-0.2)


03-06-2005VARIABLES INFLUENCING TUBULAR HYDROFORMING*Tube properties affecting Hydroforming


03-06-2005VARIABLES INFLUENCING TUBULAR HYDROFORMING*Tube properties affecting HydroformingEffect of tube expansion and corner radius:lower strength materials expands better than higher strength materials.increasing end feed didnt produce consistent effect on corner expansion.thinner gage expands well than thicker one.


03-06-2005VARIABLES INFLUENCING TUBULAR HYDROFORMING*Tube properties affecting HydroformingEffect of bursting pressure:primarily influenced by material properties and wall thickness.effect of lubricant:lubricant have negligible effect.


03-06-2005VARIABLES INFLUENCING TUBULAR HYDROFORMING*Tube properties affecting HydroformingConclusion:tube characteristics (material properties and wall thickness) have primary effect on corner expansion and bursting pressure.Friction condition (lubricant) affects wall thickness distribution and failure location. -Research carried out by Industrial Research and Development Institute


03-06-2005VARIABLES INFLUENCING TUBULAR HYDROFORMING*Development of hydroform technologyObjective:to develop process sequence and material behavior.test specimen:O.D. =63.5mmthickness = 2.3mmlength = 490mmY.S. = 340MPaT.S. = 400MPaelongation = 38.1%lubrication = anti-corrosion oil / 0.07


03-06-2005VARIABLES INFLUENCING TUBULAR HYDROFORMING*Development of hydroform technologypH=36MPaaxial stroke=40mm


03-06-2005VARIABLES INFLUENCING TUBULAR HYDROFORMING*Development of hydroform technologyEffect of loading path on thickness strain


03-06-2005VARIABLES INFLUENCING TUBULAR HYDROFORMING*Development of hydroform technologyEffect of loading path on corner radius


03-06-2005VARIABLES INFLUENCING TUBULAR HYDROFORMING*Development of hydroform technologyResult:holding pressure must be high during axial feed (but without bursting )results in better final pressure and sectional shapes


03-06-2005VARIABLES INFLUENCING TUBULAR HYDROFORMING*Influence tube material on hydroforming


03-06-2005VARIABLES INFLUENCING TUBULAR HYDROFORMING*Effect of material properties on hydroforming allowance


03-06-2005VARIABLES INFLUENCING TUBULAR HYDROFORMING*Effect of material properties on real product


03-06-2005VARIABLES INFLUENCING TUBULAR HYDROFORMING*Pillow hydroforming


03-06-2005VARIABLES INFLUENCING TUBULAR HYDROFORMING*Advantages of HydrofromingCost reduction by integration of components.Weight reduction by reducing of welded flanges for joining parts.Improvement of fatigue properties by reduction of welded joints.Improvement of component strength by forming in a closed sectional shape and work hardening.Simplification of process by hole piercing in dies and reduction of welded joints.Reduction of spring back by plastic forming.


03-06-2005VARIABLES INFLUENCING TUBULAR HYDROFORMING*Disadvantages of HydroformingForming conditions are complicated, require greater skill.Forming machines are very large and expensive.Cycle time is higher and productivity is low.Spot welding of a product with other components is difficult.


03-06-2005VARIABLES INFLUENCING TUBULAR HYDROFORMING*Application


03-06-2005VARIABLES INFLUENCING TUBULAR HYDROFORMING*ApplicationBUMPER BEAM AND ROOF RAILS


03-06-2005VARIABLES INFLUENCING TUBULAR HYDROFORMING*ApplicationROOF REINFORCEMENT


03-06-2005VARIABLES INFLUENCING TUBULAR HYDROFORMING*ApplicationMANIFOLD INLETS


03-06-2005VARIABLES INFLUENCING TUBULAR HYDROFORMING*ApplicationCHASIS STRUCTURE


03-06-2005VARIABLES INFLUENCING TUBULAR HYDROFORMING*Cross-section


03-06-2005VARIABLES INFLUENCING TUBULAR HYDROFORMING*BibliographyMetal forming handbook by SCHULERNippon technical report No.90 July 2004Industrial research and development reportTubular hydro forming of steel and aluminum alloys.www.vari-form.com


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Tubular Hydroforming

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