| Summary: | 碩士 === 國立中山大學 === 機械與機電工程學系研究所 === 102 === Lightweight and high-strength tubes have been widely used in automobile industry and other various fields recently, especially rectangular tubes. Compound processes involved hydroforming and crushing are used in manufacturing a rectangular cross-section tube of aluminum alloys AA6061-O. It is known that the internal pressure and the clamping forces of the die needed in compound process are much less than those in the expansion process.
In this study, a self-designed hydroforming test machine with a 30MPa of internal pressure and a capacity of 40 tons of axial feeding is used. Both of expansion and compound process tests will be conducted. The compound process is divided into directly crushing and crushing after preforming. A finite element simulation software DEFORM 2D is used to establish compound process analytical models with consideration of material setting, internal pressure, moving die feeding rate, and die shape. From the simulation results, thickness distribution, clamping force and forming pressure are discussed. Finally, experimental results will be compared with simulation results to verify the applicability of the finite element models.
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