Characteristics of thickness distribution of tailor-welded tube hydroforming

Both experimental and mechanical analyses were carried out to investigate the characteristics of thickness distribution for tailor-welded tube (TWT) hydroforming with dissimilar thickness. Then, the effects of weld-seam position and thickness difference were also revealed. A multiple-diameter tube was formed to reveal the characteristics and the regularity of thickness distribution during TWT hydroforming. It is indicated that there are obvious fluctuations in thickness distribution though the TWTs have the same expansion ratio. The thinning ratio of thinner tube is bigger than that of thicker tube especially in the zone closed to the weld-seam. The difference in thinning ratio between two tube segments can reach 9%. Consequently, sudden and large fluctuation of thickness appears in the zone nearby the weld-seam. The difference in thinning ratio between thinner and thicker tubes enlarges as the thickness difference increases, but improves as length ratio increases. Different strain states are the main reason to induce nonuniform thickness distribution. The difference in thickness is the main reason to induce different strain states on thinner and thicker tubes.     

轴向进给速度对内高压成形三通管影响的有限元分析

利用有限元法证实了内高压成形三通管的可行性,给出了不同轴向进给速度下零件的壁厚及应变分布,并就轴向进给速度对成形的影响进行了分析.结果表明,轴向进给速度的选取对内高压成形三通管具有重要影响.     

Influence of loading path on formability of 304 stainless steel tubes

The loading path affects the metal formability remarkably in tube hydroforming, and it is also one of the research focuses. Recently, some scholars abroad proposed a new fluctuant hydraulic loading method, which can improve the formability of tubes in hydroforming. Related studies have shown that this new loading method can improve the tube formability, the distribution of deformation is more uniform and this is useful for avoiding excessive local thinning. In this paper, tube hydroforming experiments without axial feeding were carried out; the influences of the loading methods on formability of stainless steel tubes were studied. Through the comparison of the experimental results under the condition of monotonous increase loading and fluctuation hydraulic loading, the outside diameter distribution, the thickness distribution and the crack expansion forms of deformation zone all fully prove that the uniformity of the distribution of tube deformation and formability have been increased significantly under the condition of fluctuation loading without axial feeding, the reasons should be distinguished from the fluctuation hydroforming with axial feeding. In order to study the forming mechanism, uniaxial tensile test of tubes similar to fluctuation loading deformation is designed in this paper, namely intermittent tensile test. It is found that intermittent uniaxial stretch can improve the tube elongation at fracture by about 40% and the deformation distribution is more uniform than that through uniaxial tensile test of the stainless steel tube. In the process of intermittent tensile tests, changes of metal microstructures brought by the loading and unloading processes are the main reasons that improve the formability of the tubes.     

Corner forming of AZ61A magnesium alloy tube within warm hydroforming

The corners with small radii on cross sections are crucial for forming hydroformed components with polygonal sections.In this paper,warm hydroforming experiments of AZ61A magnesium alloy tubes were carried out to study the forming regularity of round corners by using a demonstration part with square sections.Effects of temperature on radius forming,thinning ratio distribution and microstructure were revealed and a component with relative outer corner radius of 3.0 was obtained by warm hydroforming at 240℃.The minimum thickness of the formed square section was located in the transition position between the corner and the straight wall.The thinning ratio of the round corner increased with the increase of forming temperature.Formability of the magnesium tube was improved by raising temperature under the effect of dynamic recrystallization at 240℃.     

Experimental and Numerical Research on Deformation Behavior of Thin-Walledand Large Expansion Ratio Guide Vane Liner in Hydroforming Process

Some tube hydroforming process tests and further research work were conducted to manufacture hollow guide vane liners (made of super alloy GH3030).The relative thickness (t₀/OD) of the tubular blank is approximately 0.01,and the maximum expansion ratio (Dmax/OD) of the needed part is more than 40％, and the length to diameter ratio of the expansion regionis more than 3.0. It is very hard to manufacture this kind of ultra-thin-wall, curved axis and large expansion ratio tubular part without fracture and wrinkles. The success of the process is highly dependent on useful wrinkles with appropriate internal pressure and axial feeding. A simplified finite element model and a theoretical model are used for detecting the deformation behavior and forming laws. Further study results demonstrate that the useful wrinkles do not appear at the same time and middle-wrinkles need bigger axial force than tube-end-wrinkles and feeding-wrinkles. The wrinkles can transfer bigger axial force after its wave peak has come into contact with the die inner surface. The thickness thinning rate of the element at the peak is bigger than that at the trough.With the increase of the axial and hoop stress ratio, the critical buckling stress also increases. Microstructure examination results show that the grain size in the maximum thinning zone has been stretched and refined after the large deformation and annealing treatment. The process is feasible and the finished part is qualified.     

双锥形管液压成形过程中破裂和起皱的力学条件

针对双锥形管液压成形过程,分析了破裂和皱纹产生的几何及力学原因,并用数值模拟和工艺实验进行了验证。研究结果表明,有益皱纹需要同时满足几何条件和力学条件。几何条件是补料结束时形成的局部皱纹表面积略小于零件相应的表面积。力学条件是皱纹形状参数G不小于中间皱峰半径R,皱峰在后续高压整形过程中壁厚无减薄。当几何条件不满足时,即坯料任一段表面积大于零件相应表面积会起皱,过小会破裂:当力学条件不满足时,整形过程中中间皱峰发生开裂。     

变压边力对差厚拼焊板方盒形件拉深成形质量的影响

与单板相比,由于料厚比（或强度比）、焊缝性能以及成形过程中焊缝移动的影响,使拼焊板成形更为复杂。拼焊板拉深是拼焊板冲压成形中最典型成形工艺,影响拼焊板拉深成形质量的主要因素有压边力、模具几何参数、料厚比和摩擦条件等。其中,压边力的大小及加载方式对拉深成形极限及焊缝移动有着显著影响。本文采用数值模拟技术,研究了拼焊板方盒形件拉深成形过程中变压边力方案对焊缝移动及成形极限的影响规律。研究表明可以通过调整焊缝两侧板料压边力的大小,使得在尽可能满足成形深度的同时减少焊缝移动,从而提高拼焊板方盒形件的成形质量。     

管件液压成形过程的有限元分析及实验研究

以圆管变形为管球相间零件为研究对象,对液压成形这种新工艺进行研究.采用计算机数值模拟与试验相结合的方法,分析了圆管液压成形过程.管件液压成形主要有褶皱和破裂两种失效形式,而成形控制中最主要的参数之一是压力,即管件内部压力和轴向压力.在对不同加载路径进行分析后,得出模拟结果与相同条件下的实验结果比较吻合的结论.研究表明了液压成形工艺中加载路径(内压力与轴向压力的配比关系)的重要性,同时也证实了用计算机模拟仿真液压成形过程具有一定的可靠性.     

薄壁管无模内高压成形的实验研究与数值模拟

针对内压和轴压共同作用下的薄壁管无模内高压成形及加载控制稳定性问题进行了实验及数值模拟。实验结果表明,适度的起皱有助于提高薄壁管内高压成形的成形极限。有限元数值模拟证明,在轴压偏高而内压相对偏低的情况下,降低内压的增长率有助于抑制起皱的发展。出于对控制实现的考虑,有必要将内压轴压的匹配关系转换为内压轴向压缩位移的匹配关系。     

Numerical simulation and experimental investigation of incremental sheet forming process

In order to investigate the process of incremental sheet forming （ISF） through both experimental and numerical approaches, a three-dimensional elasto-plastic finite element model （FEM） was developed to simulate the process and the simulated results were compared with those of experiment. The results of numerical simulations, such as the strain history and distribution, the stress state and distribution, sheet thickness distribution, etc, were discussed in details, and the influences of process parameters on these results were also analyzed. The simulated results of the radial strain and the thickness distribution are in good agreement with experimental results. The simulations reveal that the deformation is localized around the tool and constantly remains close to a plane strain state. With decreasing depth step, increasing tool diameter and wall inclination angle, the axial stress reduces, leading to less thinning and more homogeneous plastic strain and thickness distribution. During ISF, the plastic strain increases stepwise under the action of the tool. Each increase in plastic strain is accompanied by hydrostatic pressure, which explains why obtainable deformation using ISF exceeds the forming limits of conventional sheet forming.     

方圆管固定短芯棒拉拔工艺分析

运用非线性有限元软件ABAQUS对ITER计划导体套管成形工艺进行模拟仿真,得到稳定拉拔阶段的等效塑性应变、轴向和径向应力以及接触压力的分布规律,并分析了拉拔力和拉拔成形过程中能量的分布变化。结果表明,采用优化后的工艺参数拉拔成形时可得到套管内外表面质量较好的产品,从而解决了拉拔工艺中材料内径缩孔和裂纹缺陷的问题。     

三通管内高压成形载荷路径试验优化设计

采用DYNAFORM有限元软件对三通管内高压成形过程进行了数值模拟研究,采用正交试验优化设计方法进行载荷路径参数优化,找出了T型管内高压成形的内压力、轴向进给力、背压力三参数的最优组合,采用该最优组合参数的试验结果与数值模拟结果相吻合。     

Behavior and design method of square-tubed reinforced concrete short columns under axial compression

The behavior of square-tubed reinforced concrete (STRC) short columns subjected to axial compression was studied in detail with an accurate nonlinear finite element model (FEM) . Different width to thickness ratios (D/t = 50 150) of the steel tube and the compressive strength of concrete (C80 and C50) were adopted in this research. The axial load strength,steel tube strain and load-shortening response were determined from FEM and the analysis results from FEM were compared with those from experiment. The analysis and test results indicate that the concrete strength little affectes the confinement of the steel tube on the concrete. The transverse stress of the tube at the axial load point increases with the increment in the width to thickness ratio. Based on the results from FEM and experiment,a formula for the prediction of the axial load strength was proposed in this paper.     

Deformation and defects in hydroforming of Y-shaped tubes

Hydroforming process of a Y-shaped stainless steel tube was investigated through numerical simulation and experiments. The forming process and reasons of typical defects were analyzed with three different loading paths. Thickness distribution of formed Y-shaped tube was obtained. It is shown by numerical and experimental results that the transition regions are depressed in the forming condition of low inner pressure and wrinkles occur, while fracture occurs in the forming condition of high inner pressure. After forming, the thickness in left transition fillet region is the largest, that in fight transition fillet region is thinner, and the thinnest thickness is at the top of the protrusion. The original thickness line is below the top of the protrusion. The thinning area occurs above this line, while the thickening area is below this line. The maximum thinning rate is significantly increased as the calibration pressure increases, while the maximum thickening rate remains almost unchanged.     

自应力钢管轻砼组合材料力学性能的试验研究

通过对比试验,得出了自应力钢管轻骨料混凝土中核心混凝土的膨胀规律、自应力与含钢率的关系及自应力钢管轻骨料混凝土组合材料的优越性能,分析了轴心受压短柱的破坏过程。     

圆钢管约束高强混凝土短柱的轴压力学性能

为研究圆钢管约束高强混凝土短柱的轴压力学性能,进行6个短柱试件在循环轴压荷载作用下的试验研究.试验中的主要参数为钢管径厚比(26和42).试验结果表明,圆钢管约束高强混凝土短柱的轴压承载力高于同条件的普通钢管混凝土构件,但两种构件的延性无显著差异;随钢管中纵向应力的降低,构件的轴压承载力提高.对构件的应力分析结果表明,圆钢管约束高强混凝土轴压短柱中,钢管对核心混凝土的约束效果高于普通钢管混凝土构件;钢管约束高强混凝土轴压短柱的峰值荷载点对应于钢管的屈服点.     

钢管约束的钢管混凝土轴压短柱长期变形性能

为分析钢管约束的钢管混凝土柱在长期荷载作用下的变形性能,进行了16个钢管约束的钢管混凝土短柱和2个钢管混凝土短柱的长期持荷试验,持荷时间为350 d。主要研究参数核心混凝土应力比为0.35、0.50和0.65,双层钢管总含钢率为5.8%、10.5%和15.0%,内层钢管与外层钢管含钢率比值为0.30、1.25和2.23。基于素混凝土的长期变形理论计算模型,通过分析施加纵向长期荷载时构件的受力机理,推导出适用于钢管约束的钢管混凝土轴压短柱长期变形的理论计算方法。试验结果表明：长期变形随核心混凝土应力比的提高而增大,随总含钢率、内层与外层钢管含钢率比值的增大而减小。理论计算曲线与试验数据曲线的对比和分析表明：长期变形随相对湿度的减小而增大,采用不同混凝土收缩徐变模型时,相对湿度的影响程度不同,其中CEB-FIP 2010模型的吻合效果最好。建议采用CEB-FIP 2010模型并取相对湿度为100%来计算钢管约束的钢管混凝土柱的长期变形。     

钢管再生混凝土柱在低周反复荷载作用下的试验研究

根据3个钢管再生混凝土压弯构件在水平低周反复荷载作用下的试验,考察了含钢率、轴压比两个参数变化对构件受力性能的影响,并对构件的滞回曲线、骨架曲线、刚度退化曲线进行了分析,研究构件的延性和耗能能力。研究结果表明,钢管再生混凝土试件含钢率越大,试件延性越好;轴压比越小,其延性越好。钢管再生混凝土柱在合理的含钢率和轴压比下有良好的承载能力、延性指标和耗能能力。     

圆管液压胀形过程的实验分析

圆管通过液压成形的方法可以被加工成异型截面管,本文选择了中腰鼓异型截面管为研究对象,根据变化不同的液压参数,实现对管子形状的控制,找到了一条符合要求的加载路径,为生产这类零件提供了实践参考.     

基于Dynaform的三通管件液压成形影响因素分析

通过采用Dynaform软件对三通管件液压成形过程进行模拟仿真,确定了影响其成形质量的因素,得到了各参数对管件成形的影响规律,通过控制各参数可有效地提高三通管件液压成形的质量,提高生产效率。