Abstract: This paper gives an overview of a deep drawing
process by pressurized liquid medium separated from the sheet by a
rubber diaphragm. Hydroforming deep drawing processing of sheet
metal parts provides a number of advantages over conventional
techniques. It generally increases the depth to diameter ratio possible
in cup drawing and minimizes the thickness variation of the drawn
cup. To explore the deformation mechanism, analytical and
numerical simulations are used for analyzing the drawing process of
an AA6061-T4 blank. The effects of key process parameters such as
coefficient of friction, initial thickness of the blank and radius
between cup wall and flange are investigated analytically and
numerically. The simulated results were in good agreement with the
results of the analytical model. According to finite element
simulations, the hydroforming deep drawing method provides a more
uniform thickness distribution compared to conventional deep
drawing and decreases the risk of tearing during the process.
Abstract: In recent years, global warming has become a
worldwide problem. The reduction of carbon dioxide emissions is a
top priority for many companies in the manufacturing industry. In the
automobile industry as well, the reduction of carbon dioxide emissions
is one of the most important issues. Technology to reduce the weight
of automotive parts improves the fuel economy of automobiles, and is
an important technology for reducing carbon dioxide. Also, even if
this weight reduction technology is applied to electric automobiles
rather than gasoline automobiles, reducing energy consumption
remains an important issue. Plastic processing of hollow pipes is one
important technology for realizing the weight reduction of automotive
parts. Ohashi et al. [1],[2] present an example of research on pipe
formation in which a process was carried out to enlarge a pipe
diameter using a lost core, achieving the suppression of wall thickness
reduction and greater pipe expansion than hydroforming.
In this study, we investigated a method to increase the wall
thickness of a pipe through pipe compression using planetary rolls.
The establishment of a technology whereby the wall thickness of a
pipe can be controlled without buckling the pipe is an important
technology for the weight reduction of products. Using the finite
element analysis method, we predicted that it would be possible to
increase the compression of an aluminum pipe with a 3mm wall
thickness by approximately 20%, and wall thickness by approximately
20% by pressing the hollow pipe with planetary rolls.
Abstract: During the last few years, several sheet hydroforming
processes have been introduced. Despite the advantages of these
methods, they have some limitations. Of the processes, the two main
ones are the standard hydroforming and hydromechanical deep
drawing. A new sheet hydroforming die set was proposed that has the
advantages of both processes and eliminates their limitations. In this
method, a polyurethane plate was used as a part of the die-set to
control the blank holder force. This paper outlines the Taguchi
optimization methodology, which is applied to optimize the effective
parameters in forming cylindrical cups by the new die set of sheet
hydroforming process. The process parameters evaluated in this
research are polyurethane hardness, polyurethane thickness, forming
pressure path and polyurethane hole diameter. The design of
experiments based upon L9 orthogonal arrays by Taguchi was used
and analysis of variance (ANOVA) was employed to analyze the
effect of these parameters on the forming pressure. The analysis of
the results showed that the optimal combination for low forming
pressure is harder polyurethane, bigger diameter of polyurethane hole
and thinner polyurethane. Finally, the confirmation test was derived
based on the optimal combination of parameters and it was shown
that the Taguchi method is suitable to examine the optimization
process.
Abstract: Today, Hydroforming technology provides an
attractive alternative to conventional matched die forming, especially
for cost-sensitive, lower volume production, and for parts with
irregular contours. In this study the critical fluid pressures which lead
to rupture in the workpiece has been investigated by theoretical and
finite element methods. The axisymmetric analysis was developed to
investigate the tearing phenomenon in cylindrical Hydroforming
Deep Drawing (HDD). By use of obtained equations the effect of
anisotropy, drawing ratio, sheet thickness and strain hardening
exponent on tearing diagram were investigated.