Experimental and numerical investigation of the influence of pulsating pressure on hot tube gas forming using oscillating heating

• Published in: International journal of advanced manufacturing technology Vol. 97; no. 9-12; pp. 3839 - 3848
• Main Authors: Talebi Anaraki, Ali, Loh-Mousavi, Mohsen, Wang, Li-Liang
• Format: Journal Article
• Language: English
• Published: London Springer London 01.08.2018; Springer Nature B.V
• Subjects: Aluminum base alloys; Automotive parts; CAE) and Design; Computer simulation; Computer-Aided Engineering (CAD; Deformation mechanisms; Engineering; Finite element method; Formability; Fuel consumption; Heating; Hot forming; Hydroforming; Industrial and Production Engineering; Internal pressure; Investigations; Mechanical Engineering; Media Management; Metal forming; Numerical analysis; Numerical methods; Original Article; Parameters; Plastic deformation; Pressure effects; Stress concentration; Temperature distribution; Thickness; Weight reduction; Bulging; Flame heating; Pulsating pressure; Hot metal gas forming; Improvement of formability
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-018-2228-y

Hot metal gas forming is a modern metal forming process which is generally utilized to manufacture automotive parts with complex shape and light-weight materials such as aluminum-magnesium alloys. One of the critical parameters in this approach is controlling the internal pressure of the tube during the hot forming process. The improvement of formability in tube hydroforming by utilizing pulsating pressure paths has been confirmed in the last few years. In this paper, the effect of the pulsating pressure on the hot tube gas bulging process has been investigated by experimental and numerical methods. In addition, an oscillating heating mechanism was used to provide a uniform temperature distribution along the tube. A novel, simple pneumatic system was designed and used to provide pressure paths. Moreover, the finite element simulation of hot tube gas bulging was carried out to investigate the effect of different parameters of pulsating pressure on tube formability and thickness distribution. The simulation and experimental results showed that the proposed pulsating pressure path improved formability and thickness distribution along the tube in the hot metal tube gas bulging process. It was also concluded that the axial feeding intensifies the effect of pulsating pressure on formability and it should be applied right after the start of the plastic deformation of the tube.