Deformation analysis of double-sided tube hydroforming in square-section die |
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| Affiliation: | 1. Institute for Microstructural and Mechanical Process Engineering, The University of Sheffield, Mappin Street, Sheffield S1 3JD, UK;2. Advanced Forming Research Centre, University of Strathclyde, Glasgow PA4 9LJ, UK;3. Tata Steel Europe, Swinden Technology Centre, Moorgate Road, Rotherham S60 3AR, UK;4. Magnesium Elektron, 1001 College Street, P.O. Box 258, Madison, IL 62060, USA;1. School of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China;2. China Science Lab, General Motors, 56 Jinwan Road, Shanghai 201206, PR China;1. Department of Mechanical and Aerospace Engineering, Missouri University of Science and Technology, Rolla, MO 65409, United States;2. Department of Materials Science and Engineering, Missouri University of Science and Technology, Rolla, MO 65409, United States;1. National Research Laboratory for Computer Aided Materials Processing, Department of Mechanical Engineering, KAIST, 291 Daehak-ro, Yuseong-gu, Daejeon 305-701, Republic of Korea;2. Wire Rod Research Group, Technical Research Laboratories, POSCO, 1 Goedong-dong, Nam-gu, Pohang, Gyeongbuk 790-785, Republic of Korea;3. Materials Deformation Department, Korea Institute of Materials Science, 797 Changwondaero, Changwon, Gyeongnam 642-831, Republic of Korea;1. Lehrstuhl für Umformtechnik und Gießereiwesen, Technische Universität München, Walther-Meißner-Straße 4, 85748 Garching, Germany;2. Österreichisches Gießerei-Institut, Parkstraße 21, 8700 Leoben, Austria;3. Miba Gleitlager GmbH, Dr.-Mitterbauer-Straße 3, 4663 Laakirchen, Austria |
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| Abstract: | In this paper, in order to explore the deformation behavior of double-sided tube hydroforming in square-section die, effect of external pressure on the critical effective strain was theoretically analyzed firstly. And then a special experimental setup was designed for double-sided tube hydroforming in which the difficulty of simultaneous loading was overcome using two independent intensifiers and servo controlling while the sealing of external pressure was guaranteed by the O rings assembled in the interfaces of mandrel/base plate and outer cylinder/base plate. Furthermore, 5A02-O aluminum alloy tubes with outer diameter of 63 mm and thickness of 2 mm were investigated under different external pressures varying from 0 to 80 MPa. At the same time, numerical simulation was conducted using the Abaqus/Explicit software. It is shown that increasing of external pressure has an effect on the fraction of grain boundaries, the number and size of the microvoids and the microhardness in the transition zone, and thus increases the critical effective strain in the transition zone. It can be concluded that the deformation ability of the transition zone is improved by the external pressure in double-sided tube hydroforming of square-section. This investigation shows that double-sided tube hydroforming is a potential forming method for the fabrication of lightweight hollow structures using the tubes with low ductility. |
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| Keywords: | Double-sided tube hydroforming External pressure 5A02 aluminum alloy Transition zone Microstructure |
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