Finite Element Simulation and Die Design for Tube Hydro-piercing Processes

• Main Authors: Wei-Han Dai, 戴煒翰
• Other Authors: Yeong-Maw Hwang
• Format: Others
• Language: zh-TW
• Published: 2016
• Online Access: http://ndltd.ncl.edu.tw/handle/71155929040532524115

碩士 === 國立中山大學 === 機械與機電工程學系研究所 === 104 === This study is focused on the design of the punch shape and die in tube hydro-piercing processes. At first, the material parameters of carbon steel SPFC590Y and aluminum alloy 6005 are obtained using tensile tests. Aluminum alloy 6005 tubes are annealed to investigate the effects of material ductility on hydro-piercing processes. The flow stress curves obtained are used in the finite element simulations of tube hydro-piercing process with software “Deform 3D”. Ductile fracture criterion of Normalized Cockcroft and Latham is used during the simulations. The critical damage values for the criterion are obtained by comparing simulation results and tensile test data. The effects of various parameters such as the stroke, internal pressure, etc. on hydro-piercing processes and deformation mechanism are discussed. Experiments are conducted to compare with the simulation results to verify the validity of the analytical models. At first, the die design of hydro-piercing processes were conducted, and then the effects of various parameters on shearing surface are discussed by experiments of hydro-piercing. The experimental results show the same trends with simulation results in the effects of internal pressure, punch shape and stroke on shearing surface. Finally formula for the relationship between residual thickness, internal pressure, stroke and tube thickness are developed by regression analysis. Analytical values from the parameters formula are compared with simulation data to verify the validity of the formula. The formula is useful for process control in the hydro-piercing processes.