PNNL

Abstract

This paper employs an inverse approach (IA) formulation for the analysis of tubes under free hydroforming conditions. The IA formulation is derived from that of Guo et al. established for flat sheet hydroforming analysis using constant strain triangular membrane elements. At first, an incremental analysis of free hydroforming for a hot-dip galvanized (HG/Z140) DP600 tube is performed using the finite element Marc code. The deformed geometry obtained at the last converged increment is then used as the final configuration in the inverse analysis. This comparative study allows us to assess the predicting capability of the inverse analysis. The results will be compared with the experimental values determined by Asnafi and Skogsgardh. After that, a procedure based on a forming limit diagram (FLD) is proposed to adjust the process parameters such as the axial feed and internal pressure. Finally, the adjustment process is illustrated through a re-analysis of the same tube using the inverse approach