Prediction Accuracy of Failure Criteria in FE-analyses of Hydroforming Processes

• Autorzy: Hartl C. , Radetzky M.
• Języki publikacji: EN

Abstrakty

EN

Simulations of tube hydroforming processes require a reliable prediction of the occurrence of plastic instabilities, which are limiting the maximum feasible expansion of the formed tube. To determine the onset of necking, as one of the important instabilities in hydroforming, the use of forming limit diagrams is a well-established practice. This method was initially developed for sheet metal forming processes and is commonly applied also for hydroforming, in spite of the fact that the prediction accuracy depends on the strain path at the analysed position of the formed component. To establish according forming limit diagrams, experimental as well as theoretical techniques exist. Ductile fracture criteria, based on the calculation of forming-history-dependent damage values and considering the development of continuum variables such as stress and strain, are alternative methods of failure prognostication and appealing because of their simplicity. Against the background to obtain an information about the quality in failure prediction of theoretically determined forming limit diagrams and damage-value-based methods for hydroforming component design, an evaluation of , selected examples, of these methods was conducted using simulations with the finite element method. To enable a reliable comparison with experiments, published results of aluminium tube hydroforming were taken where load paths for the forming operation were applied which resulted in a predominantly constant strain ratio at the point of maximum expansion. It was found that the investigated criteria resulted in different prognostication for the onset of plastic instability.

Słowa kluczowe

EN

hydroforming; necking; failure criteria

• Wydawca: Oficyna Wydawnicza Politechniki Warszawskiej
• Czasopismo: Machine Dynamics Research
• Rocznik: 2014
• Tom: Vol. 38, No. 4
• Strony: 69--77
• Opis fizyczny: Bibliogr. 22 poz., wykr.

Twórcy

autor

Hartl C.

• Cologne University of Applied Sciences, Cologne, Germany

autor

Radetzky M.

• Cologne University of Applied Sciences, Cologne, Germany

Bibliografia

• 1. Ch. HartI: “Deformation mechanism and fundamentals of hydroforming”, in M. Koç, Hydroforming fo r advanced manufacturing, Cambridge Woodhead Publishing, pp. 52-76, 2008.
• 2. Ch. Hartl: “Research and advances in fundamentals and industrial application of hydroforming”, J. Mat. Proc. Technol., v. 167, pp. 383-392, 2005.
• 3. D.E. Green: “Formability analysis for tubular hydroformed parts”, in M. Koç, Hydroforming for advanced manufacturing, Cambridge, Woodhead Publishing, pp. 93-120, 2008.
• 4. M. Jansson, L. Nilsson, K. Simonsson: “On strain localisation in tube hydroforming of aluminium extrusions”, J. Mat. Proc. Technol., v. 195, pp. 3-14, 2008.
• 5. P.B. Mellor: “Tensile instability in thin-walled tubes”, Int. J. Mech. Eng. Sci, v. 4, pp. 251-256, 1962.
• 6. W.J. Sauer, A. Gotera, F. Robb, P. Huang: “Free bulge forming of tubes under internal pressure and axial compression”, in proceedings of 6th North American metal working research conference, Gainsville, Apr. 16-19, pp. 228-235, 1978.
• 7. E. Chu, Y. Xu: “Influences of generalized loading parameters on FLD prediction for aluminium tube hydroforming”, J. Mat. Proc. Technol., v. 196, pp. 1-9, 2008.
• 8. M .J. Hillier: “Tensile plastic instability under complex stress”, Int. J. Mech Sci., v. 5, pp. 57-67, 1962.
• 9. G. Nefussi, A. Combescure: “Coupled buckling and plastic instability for tube hydroforming”, Int. J. Mech. Sci., v. 44, pp. 899-914, 2002.
• 10. Y. Yamada, I. Aoki: “On the tensile plastic instability in axi-symmetric deformation of sheet metals”, J. JSTP, v. 7, pp. 393-406, 1966.
• 11. H.L. Xing, A. Makinouchi: “Numerical analysis and design for tubular hydroforming”, Int. J. Mech. Sci., v. 43, pp. 1009-1026, 2001.
• 12. R. Hill: “A general theory of plastic deformation and instability in thin-walled tubes under combined loading”, J. Mech. Phys. Solids, v. 44, pp. 2041-2057, 1996.
• 13. E. Chu, Y. Xu, R.W. Davies, G.J. Grant: (2006), “Failure predictions for aluminium tube hydroforming processes”, SAE Techn. Paper Ser., 2006-1-0543, 2006.
• 14. H.W. Swift: “Plastic instability under plane stress”, J. Mech. Phys. Solids, v. 1, pp. 1-8, 1952.
• 15. R. Hill: “On discontinuous plastic states, with special reference to localized necking in thin sheets”, J. Mech. Phys. Solids, v. 1, pp. 19-30, 1952.
• 16. Y. Hwang, Y.K. Lin, H.-C. Chuang: “Forming limit diagrams of tubular materials by bulge tests", J. Mat. Proc. Technol., v. 209, pp. 5024-5034, 2009.
• 17. M. Saboori, J. Gholipour, H. Chamliaud, A. Gakwaya, J. Savoie, P. Wanjara: “Prediction of burst pressure using a decoupled ductile fracture criterion for tube hydroforming of aerospace alloys”, in proceedings of Int. ESAFORM Conference on Material Forming, Belfast, Northern Ireland, Apr. 27-29, pp. 301-306, 2011.
• 18. M.G. Cockcroft, D.J. Latham: “Ductility and the workability of metals”, J. Ind. Metals, v. 96, pp. 33-39, 1968.
• 19. S.I. Oh, C.C. Chen, S. Kobayashi: “Ductile fracture in axisymmetric extrusion and drawing”, J. Eng. Ind., v. 101-102, pp. 36-44, 1979.
• 20. P. Brozzo, B. Deluka, R. Rendina: “A new method for the prediction of formability in metal sheets“, in proceedings of 7th Biennale Congr. IDDRG, Amsterdam, 1972.
• 21. C. Butcher, Z. Cheng, A. Bardelcik, M. Worswick: “Damage-based fmite-element modelling of tube hydroforming”, Int. J. Fracture, v. 155, pp. 55-65, 2009.
• 22. J. Crapps, E.B. Marin, M.F. Horstmeyer, R. Yassar, P.T. Wang: “Internal state variable plasticity-damage modeling of the copper tee-shaped tube hydroforming process”, J. Mat. Proc. Technol., v. 210, pp. 1726-1737, 2010.