Tube diameter effect on formability of tube hydroforming was investigated for a vehicle bumper rail section. Four types of loading path were considered and, with changing tube diameter, paths for reducing thinning were identified. By slightly changing diameter only by about 10% (from 90 to 100mm), remarkable reduction to about one-third in thinning rate and more uniform thickness distribution were predicted whichever loading path was applied to the prediction. Also, for tube with smaller diameter than 100 mm (PR = 87.3) feeding was much more influential on suppressing excessive thinning than pre-pressure before tool closed. The benefit from pre-pressure became more distinct as tube diameter become large over 100 up to 110 mm (PR = 96.1) so that, for the 110 mm diameter tube, the pre-pressure was far more effective than feeding for formability including the thinning. The tube with diameter over the limit, which cannot be manufactured by a conventional tool with horizontal split planes, could be successfully hydroformed by utilizing tool with slant split planes and applying only internal pressure without both feeding and pre-pressure. Consequently, for ensuring high formability in tube hydroforming, it is of great importance to select a starting tube with as large diameter as possible through precise examination on tube crushing behavior during tool closing. And, for the selected tube size, a promising loading path should be determined. Also, application of a tool with slant split planes could be an efficient hardware method to improve formability, and it requires further systematic study.


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    Title :

    Tube size effect on hydroforming formability


    Contributors:

    Published in:

    Publication date :

    2005


    Size :

    10 Seiten, 16 Bilder, 4 Tabellen, 14 Quellen




    Type of media :

    Article (Journal)


    Type of material :

    Print


    Language :

    English




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