PNNL

Abstract

This paper describes the development of a solution control method that tracks the stresses, strains and mechanical behavior of a tube during hydroforming to estimate the proper axial feed (end-feed) and internal pressure loads through time. The analysis uses the deformation theory of plasticity and Hill?s criterion to describe the plastic flow. Before yielding, the pressure and end-feed increments are estimated based on the initial tube geometry, elastic properties and yield stress. After yielding, the pressure increment is calculated based on the tube geometry at the previous solution increment and the current hoop stress increment. The end-feed increment is computed from the increment of the axial plastic strain. Limiting conditions such as column buckling (of long tubes), local axi-symmetric wrinkling of shorter tubes, and bursting due to localized wall thinning are considered. The process control method has been implemented in the Marc finite element code. Hydroforming simulations using this process control method were conducted to predict the load histories for controlled expansion of 6061-T4 aluminum tubes within a conical die shape and under free hydroforming conditions. The predicted loading paths were transferred to the hydroforming equipment to form the conical and free-formed tube shapes. The model predictions and experimental results are compared for deformed shape, strains and the extent of forming at rupture.