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Development of Thick Tube Hydroforgi...

Alzahrani, Bandar Abdulrahman.

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Development of Thick Tube Hydroforging Process.

Record Type:	Electronic resources : Monograph/item
Title/Author:	Development of Thick Tube Hydroforging Process./
Author:	Alzahrani, Bandar Abdulrahman.
Description:	149 p.
Notes:	Source: Dissertation Abstracts International, Volume: 77-10(E), Section: B.
Contained By:	Dissertation Abstracts International77-10B(E).
Subject:	Mechanical engineering. -
Online resource:	http://pqdd.sinica.edu.tw/twdaoapp/servlet/advanced?query=10110548
ISBN:	9781339737935

Development of Thick Tube Hydroforging Process.
Alzahrani, Bandar Abdulrahman.

Development of Thick Tube Hydroforging Process. - 149 p.

Source: Dissertation Abstracts International, Volume: 77-10(E), Section: B.

Thesis (Ph.D.)--North Carolina State University, 2015.

Tube hydroforging is a hybrid forming operation whereby a thick tube is formed to a desired geometry by combining forging and hydroforming operations. Through this process hollow structures with high strength-to-weight ratio can be produced for applications in tube fittings, automotive parts, power transmission systems, etc. In this process, a thick tube is deformed by pressurized fluid contained within the tube using a multi-purpose punch assembly, which is also used to feed tube material into the die cavity. The pressure is generated by compressing the fluid volume contained within the tube which plastically deformed the tube.

ISBN: 9781339737935Subjects--Topical Terms:

649730
Mechanical engineering.

Development of Thick Tube Hydroforging Process.
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020 $a 9781339737935
035 $a (MiAaPQ)AAI10110548
035 $a AAI10110548
040 $a MiAaPQ $c MiAaPQ
100 1 $a Alzahrani, Bandar Abdulrahman. $3 3194163
245 1 0 $a Development of Thick Tube Hydroforging Process.
300 $a 149 p.
500 $a Source: Dissertation Abstracts International, Volume: 77-10(E), Section: B.
500 $a Adviser: Gracious Ngaile.
502 $a Thesis (Ph.D.)--North Carolina State University, 2015.
520 $a Tube hydroforging is a hybrid forming operation whereby a thick tube is formed to a desired geometry by combining forging and hydroforming operations. Through this process hollow structures with high strength-to-weight ratio can be produced for applications in tube fittings, automotive parts, power transmission systems, etc. In this process, a thick tube is deformed by pressurized fluid contained within the tube using a multi-purpose punch assembly, which is also used to feed tube material into the die cavity. The pressure is generated by compressing the fluid volume contained within the tube which plastically deformed the tube.
520 $a The tube hydroforging process combined tube hydroforming and forging operation. The tube hydroforming process is capable of producing light weight and stronger structure, however, it is limited to thin tube due to the high equipment cost. On the other hand, forging process is limited to bulky parts which need extra processing for weight reduction. By combining these processes, tube hydroforging is capable of producing structures in which both strength and weight reduction can be achieved in parts such as hollow vessels, hollow polygon shaped flanges, and hollow power transmission parts.
520 $a In this research, the tube hydrforging process is developed by establishing the process design guidelines. The process design guidelines consists of the establishment of process windows for potential part geometries, determination of pressure and feed load path by means of analytical/numerical models, and designing a hydroforging system to investigate the process capability of producing sound parts. Firstly, the process feasibility was examined by establishing the process windows for potential part geometries based on tube and fluid volume calculations. Secondly, to establish desirable pressure and feed load path, combined analytical and numerical models were introduced. An analytical model to determine initial pressure and feed loading paths is formulated for the hydroforging process. The model is derived based on plasticity theory and deformed shape evolution. Stepwise solution schemes are used to calculate instantaneous pressure, material feed, stresses, strains, and other geometrical parameters. The pressure equation derived in the model include a multiplication factor beta which works as pressure scaling factor. The multiplication factor with beta values in the range (0.0 ≤ beta ≤ 0.5) are used to establish the initial pressure profiles which can be refined to obtain optimal pressure and feed load path through finite element simulations. The pressure and feed load path can be considered optimal when sound product is obtained. Although the derived model is focused on simple bulged flanges, it can be extended for other complex shapes. Finally, hydroforging experiments were carried out for different potential parts using different tube sizes, tube materials, and die inserts to examine the hydroforging process capability of producing potential parts.
520 $a It was found that variety of potential parts were feasible to form by hydroforging process. The analytical-numerical model output showed that beta values between 0.0 and 0.2 were suitable to obtain a successful part for most of the geometries and tube thicknesses investigated for aluminum tubes. beta values between 0.3 and 0.5 were found to be suitable to obtain successful parts for most of the geometries and tube thicknesses investigated for stainless steel tubes. The applicability of the FE model in predicting the thickness distribution of the formed parts was verified by comparing the numerical results and the experimental results with maximum error of 8%. It is also found that the pressure and feed load path has a great influence on the part quality. Uniformed thickness distribution can be eliminated by applying a proper pressure and feed load path. The experimental results showed that the hydroforging process is capable of producing hollow structures such as hollow vessels, hollow polygon shaped flanges and hollow gears. Weight reduction by over 50% can be achieved when hollow gears are formed by hydroforging process compared to the solid gears currently produced by conventional forging processes. To facilitate the input of optimal pressure and feed load path in a hydroforging system, a robust closed feedback control unit should be built.
590 $a School code: 0155.
650 4 $a Mechanical engineering. $3 649730
650 4 $a Mechanics. $3 525881
650 4 $a Engineering. $3 586835
690 $a 0548
690 $a 0346
690 $a 0537
710 2 $a North Carolina State University. $b Mechanical Engineering. $3 3179478
773 0 $t Dissertation Abstracts International $g 77-10B(E).
790 $a 0155
791 $a Ph.D.
792 $a 2015
793 $a English
856 4 0 $u http://pqdd.sinica.edu.tw/twdaoapp/servlet/advanced?query=10110548