Numerical and experimental predictions of formability parameters in tube hydroforming process

ABSTRACT

The purpose of this study is to improve the bulging and minimise the thinning ratio so that manufacturing processes will be improved in Industries. Tube hydroforming is an advanced manufacturing technology used for making intricate and complex tubular parts which required less cycle time. This research focusses on hydroforming process, formability and process parameters design for replacing the conventional tube bending, welding and cutting operations. The prediction of parameters is done by applying numerical and experimental approach. During experimentation the pressurised fluid is used to deform the tubes in a plastic deformation. In this study, two types of grade materials are used such as AISI304 and AISI409Lof 57.15 mm external diameter with 1.5 mm thickness in the form of ERW tubes to measure stain path, thinning and bulge height. However, it is observed that the internal pressure and L/D ratio are effective parameters in both numerical analysis and experimentation. In axial feed condition, it is observed that 7.7% thinning in weld region and 24.9% thinning in base metal region, whereas, in fixed feed condition, it is observed that 9.2% thinning in weld region and 26.2% thinning in base metal region for L/D = 1 and L/D = 3, respectively. The numerical analysis with experimental results shows a very good match.

KEYWORDS:

• Tube hydroforming (THF)
• formability
• numerical analysis
• bulging
• thinning

Nomenclature

Table

Acknowledgments

The Authors would like to thank Dr.K. Narasimhan, IIT Bombay and Mr. A. Omarfor providing valuable guidance and support. Also, we would like to express my sincere gratitude to Dr. V.M. Nandedkar for providing an opportunity to work under them.

Data availability statement

Data sharing is not applicable to this article as the data that support the findings of this study are available within the article.

Disclosure statement

The authors declare that there is no conflict of interests regarding the publication of this paper.

Additional information

Funding

This work is not supported fully or partially by any funding organization or agency.

Notes on contributors

Bapurao G. Marlapalle

Bapurao G. Marlapalle is Ph.D. research scholar in Mechanical Engineering at JSPM Rajarshi Shahu College of Engineering, Tathawade, Pimpri-Chinchwad, Maharashtra. He is also currently associated with Deogiri Institute of Engineering and Management Studies (DIEMS), Aurangabad as an Assistant Professor in Mechanical Engineering. He joined the institute in July 2012. He is member of ISTE, SAE. His area of interest includes, design engineering, CAD/CAE, manufacturing engineering. He is having more than 8 years teaching and research experience. 

Rahulkumar S. Hingole

Rahulkumar S. Hingole has received Ph.D. degree in Mechanical Engineering from SGGSI&E, Vishnupuri Nanded. He is currently associated with JSPM Rajarshi Shahu College of Engineering, Tathawade, Pimpri-Chinchwad, Maharashtra as a Research Guide. He is also working as professor in in Mechanical Engineering at Dr. D. Y. Patil College of Engineering, Pune. He is member of ISTE, ASME, Sheet Metal Forming Research Association, SAE. His area of interest includes, machine design engineering, manufacturing engineering,Metal Forming, CAD/CAM and Automation. He is having more than 20 years teaching and research experience.