RESEARCH ON THE FREE BULGING STAGE IN HYDROSTATIC FORMING PROCESS FOR COPPER SHEET
Hydrostatic forming is one of the most advanced technologies for forming tubular and sheet products. This technology has been highly applied in thin-shell manufacturing industries, especially in the automotive industry. However, the depth of the parts formed by this technology is limited by the early stage-the free bulging stage due to intense thinning of the metal. Therefore, it is necessary to control the thinning in this stage to ensure that the material can continue to deform in later stages. The types of materials used in this technology are also common materials as in conventional forming including ferrous and non-ferrous metals. Among them, copper materials with ductile properties are considered as one of the most popular. Copper behavior in the forming technology is still a new issue that needs to be explored. Therefore, in this paper, the free bulging process is studied during hydrostatic forming process for copper sheet using numerical simulation. The results show the influence of forming liquid pressure on the forming ability of copper materials, including forming depth and thinning in the free bulging phase.
Hartl, C.: Research and advances in fundamentals and industrial applications of hydroforming. Journal of Materials Processing Technology, 2005, 167(2-3), pp. 383-392. doi:10.1016/j. jmatprotec.2005.06.035
Oh, S.-I., Jeon, B.-H., Kim, H.-Y., & Yang, J.-B.: Applications of hydroforming processes to automobile parts. Journal of Materials Processing Technology, 2006, 174(1), pp. 42-55. doi:10.1016/j. jmatprotec.2004.12.013.
Huiwen, H., Wang, J.-F, Fan, K.-T., Chen, T.-y., Wang, S.-Y., Development of sheet hydroforming for making an automobile fuel tank, In: Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture, 2015, Vol. 229, Doi: 10.1177/0954405414554666.
Bell, C., J. Corney, N. Zuelli, and D. Savings, “A state of the art review of hydroforming technology,” Int. J. Mater. Form., 2019, 10.1007/s12289-019-01507-1.
Yaghoobi, A., Bakhshi-Jooybari, M., Gorji, A., Baseri, H., Application of adaptive neuro fuzzy inference system and genetic algorithm for pressure path optimization in sheet hydroforming process. International Journal of Advanced Manufacturing Technology, 2016, Vol. 86, No. 9, pp. 2667-2677, doi: 10.1007/s00170-016-8349-2.
Taye, F. F., & Ravi, K. D.: Enhancement of drawability of cryorolled AA5083 alloy sheets by hydroforming. Journal of Materials Research and Technology, 2019, 8(1), pp. 411-423. doi:10.1016/j. jmrt.2018.02.012
Maki, T., & Cheng, J.: Sheet Hydroforming and Other New Potential Forming Technologies. IOP Conference Series: Materials Science and Engineering, 2018, 418, 012117. doi:10.1088/1757-899x/418/1/012117
ZahedI, S. A., H.Goodarzian, M.Okazi, & Bakhshi-Jooybari, M.: Investigation of conventional deep drawing and hydroforming deep drawing via experimental and finite element simulation. Indian Journal of Science and Technology, 2010, 3(9), pp. 1009-1013. doi:10.17485/ijst/2010/v3i9/29878
Koller, D., Ulbrich, S. J. P. i. A. M., & Mechanics. Optimal control of hydroforming processes, 2011, 11(1), pp. 795-796
Marandi, F. A., Jabbari, A. H., Sedighi, M., & Hashemi, R.: An Experimental, Analytical, and Numerical Investigation of Hydraulic Bulge Test in Two-Layer Al–Cu Sheets. Journal of Manufacturing Science and Engineering, 2017, 139(3), 10. doi:10.1115/1.4034717
R. Krux, W. Homberg, M. Kalveram, M. Trompeter, M. Kleiner and K. Weinert, Die Surface Structures and Hydrostatic Pressure System for the Material Flow Control in High-Pressure Sheet Metal Forming. Advanced Materials Research, 2005, Vols. 6-8, pp. 385-392.
Modi, B., Kumar, D. Ravi. Optimization of process parameters to enhance formability of AA 5182 alloy in deep drawing of square cups by hydroforming. Journal of Mechanical Science and Technology, 2019, 33(11), pp. 5337-5346. doi:10.1007/s12206-019-1026-2
Valentin Gagov, B. T., Rossen Radev and Emil Yankov. About the sheet metal testing by hydraulic bulging. Int. J. Microstructure and Materials Properties, 2009, 4.
Nguyen Thi Thu, Nguyen Dac Trung, On the thickness distribution and the maximum thinning ratio in hydrostatic forming for sheet metal. International Journal of Modern Physics B, 2020. DOI: 10.1142/S021797922040144X.