Finite Element Simulation Of Shaped Tube Hydroforming

Hydroforming technology, the rapid development of its unique advantages, has become a new research direction in the field of plastic forming. However, hydroforming is a relatively young technology, theory and application, there are many issues to be studied.In this paper,the hydroforming of shaped tube is studied by theoretical analysis,finite element simulation and experimental study,the forming rules of the process paramenters on the shaped tube hydroforming properties are discussed.The finite element software DYNAFORM was used to simulate the shaped tube hydroforming.The influence of the main process paramenters such as internal pressure,axial feed and wall thickness of the original tube on the forming properties ware discussed, the optimum paramenter combination of forming tapical shaped tube was identified.Simulation results show that the pressure and axial feed is the key paramenters which impact the minimum wall thickness of the formed parts. The role of internal pressure makes the minimum wall thickness value decreases. Axial feed can properly control the minimum wall thickness to reduce.However,the success forming must be reasonable combination of the two. According to shaped tube forming characteristics,internal pressure using the bilinear loading menthod,exerting sufficient axial feed in the initial forming part of low pressure, and then high-pressure shaping, formed a qualified part. Also analyzed the influence of the original tube wall thickness on the tube forming properties, indicating that the larger the original wall thickness, the better the tube formability, but the corresponding need for higher forming pressure.Finally,the material flow pattern of the shaped tube hydroforming was discussed.Studies shown that under the effect of axial punch,material of the tube ends flowing to the middle,the material of the tube middle flowing to deformation direction,the greater the deformation,the faster the speed of the material flow.According to the requirements and features of shaped tube hydroforming process, design an experimental mold device and the main hydraulic circuit of the hydraulic control system. Finally, based on the optimum parameter combination forming simulation for experimental research, the error of the study results and simulation results is less which confirmed the correctness of the simulation results. That finite element simulation techniques to determine the hydroforming process parameters is an effective method.