Investigation of Punch Shape and Loading Path Design in Hydro-Flanging Processes of Aluminum Alloy Tubes
Hydro-joining is composed of hydro-piercing, hole flanging and nut-inlaying processes. In this study, a new hydro-flanging process combining hydro-piercing and hydro-flanging is proposed. An internal pressured fluid is used as the supporting medium instead of a rigid die. Three kinds of punch head s...
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doaj-5ad5814f38ab4d23bbd798a66901a5952021-04-13T23:06:42ZengMDPI AGMetals2075-47012021-04-011163663610.3390/met11040636Investigation of Punch Shape and Loading Path Design in Hydro-Flanging Processes of Aluminum Alloy TubesYeong-Maw Hwang0Hong-Nhan Pham1Hiu-Shan Rachel Tsui2Department of Mechanical and Electro-Mechanical Engineering, National Sun Yat-Sen University, Lien-Hai Rd., Kaohsiung 804, TaiwanDepartment of Mechanical and Electro-Mechanical Engineering, National Sun Yat-Sen University, Lien-Hai Rd., Kaohsiung 804, TaiwanDepartment of Mechanical and Electro-Mechanical Engineering, National Sun Yat-Sen University, Lien-Hai Rd., Kaohsiung 804, TaiwanHydro-joining is composed of hydro-piercing, hole flanging and nut-inlaying processes. In this study, a new hydro-flanging process combining hydro-piercing and hydro-flanging is proposed. An internal pressured fluid is used as the supporting medium instead of a rigid die. Three kinds of punch head shapes are designed to explore the thickness distribution of the flanged tube and the fluid leakage effects between the punch head and the flanged tube in the hydro-flanging process. A finite element code DEFORM 3D is used to simulate the tube material deformation behavior and to investigate the formability of the hydro-flanging processes of aluminum alloy tubes. The effects of various forming parameters, such as punch shapes, internal pressure, die hole diameter, etc., on the hydro-flanged tube thickness distributions are discussed. Hydro-flanging experiments are also carried out. The die hole radius is designed to make the maximum internal forming pressure needed smaller than 70 MPa, so that a general hydraulic power unit can be used to implement the proposed hole flanging experiments. The flanged thickness distributions are compared with simulation results to verify the validity of the proposed models and the designed punch head shapes.https://www.mdpi.com/2075-4701/11/4/636tube hydroforminghydro-flangingpunch head shapefinite element analysisalumimum alloy |
collection |
DOAJ |
language |
English |
format |
Article |
sources |
DOAJ |
author |
Yeong-Maw Hwang Hong-Nhan Pham Hiu-Shan Rachel Tsui |
spellingShingle |
Yeong-Maw Hwang Hong-Nhan Pham Hiu-Shan Rachel Tsui Investigation of Punch Shape and Loading Path Design in Hydro-Flanging Processes of Aluminum Alloy Tubes Metals tube hydroforming hydro-flanging punch head shape finite element analysis alumimum alloy |
author_facet |
Yeong-Maw Hwang Hong-Nhan Pham Hiu-Shan Rachel Tsui |
author_sort |
Yeong-Maw Hwang |
title |
Investigation of Punch Shape and Loading Path Design in Hydro-Flanging Processes of Aluminum Alloy Tubes |
title_short |
Investigation of Punch Shape and Loading Path Design in Hydro-Flanging Processes of Aluminum Alloy Tubes |
title_full |
Investigation of Punch Shape and Loading Path Design in Hydro-Flanging Processes of Aluminum Alloy Tubes |
title_fullStr |
Investigation of Punch Shape and Loading Path Design in Hydro-Flanging Processes of Aluminum Alloy Tubes |
title_full_unstemmed |
Investigation of Punch Shape and Loading Path Design in Hydro-Flanging Processes of Aluminum Alloy Tubes |
title_sort |
investigation of punch shape and loading path design in hydro-flanging processes of aluminum alloy tubes |
publisher |
MDPI AG |
series |
Metals |
issn |
2075-4701 |
publishDate |
2021-04-01 |
description |
Hydro-joining is composed of hydro-piercing, hole flanging and nut-inlaying processes. In this study, a new hydro-flanging process combining hydro-piercing and hydro-flanging is proposed. An internal pressured fluid is used as the supporting medium instead of a rigid die. Three kinds of punch head shapes are designed to explore the thickness distribution of the flanged tube and the fluid leakage effects between the punch head and the flanged tube in the hydro-flanging process. A finite element code DEFORM 3D is used to simulate the tube material deformation behavior and to investigate the formability of the hydro-flanging processes of aluminum alloy tubes. The effects of various forming parameters, such as punch shapes, internal pressure, die hole diameter, etc., on the hydro-flanged tube thickness distributions are discussed. Hydro-flanging experiments are also carried out. The die hole radius is designed to make the maximum internal forming pressure needed smaller than 70 MPa, so that a general hydraulic power unit can be used to implement the proposed hole flanging experiments. The flanged thickness distributions are compared with simulation results to verify the validity of the proposed models and the designed punch head shapes. |
topic |
tube hydroforming hydro-flanging punch head shape finite element analysis alumimum alloy |
url |
https://www.mdpi.com/2075-4701/11/4/636 |
work_keys_str_mv |
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