Tribological Issues in the Tube Hydroforming Process—Selection of a Lubricant for Robust Process Conditions for an Automotive Structural Frame Part

[+] Author and Article Information
Muammer Koç

Department of Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109

J. Manuf. Sci. Eng 125(3), 484-492 (Jul 23, 2003) (9 pages) doi:10.1115/1.1580526 History: Received November 01, 2001; Online July 23, 2003; Revised December 01, 2003
Copyright © 2003 by ASME
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Sequence of forming operations in a typical hydroforming process, (b) Some automotive parts candidate forming with hydroforming
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Schematic of hydroforming of a simple bulge, and various friction zones in a typical hydroforming process
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Some of the existing friction testing apparatus for hydroforming. (a) University of Darmstadt’s testing tooling for guiding zone friction measurements 836, (b) OSU’s test tooling for guiding zone friction measurements 37, (c) OSU’s test tooling for expansion zone friction measurements 37
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Structural hydroform part used this experiment and overall dimensions
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Comparison of minimum thickness measurements in regions B, C, and D for respective lubricants. Tubes with two different initial thickness values (3 and 4 mm) were tested. Lubricant 2 offers the least amount of thinning when all regions and different initial tube thickness conditions are considered.
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(a & b) Comparison of axial force readings for respective lubricants on parts with two different initial tube thickness values. (c) Comparison of punch positions (not real feeding) for parts with initial thickness of 4 mm. Lube 2 performs the best in terms of the smallest force requirements and largest total axial feeding capability.
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Comparison of (a) overall box dimension (height and width) deviation at all regions. (b) Comparison of flatness at Region B and Region C (c) Comparison of overall radius deviation at all regions. None of these measurements indicates a clear result.
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(a) FE Model, (b, c, d) forming sequence, (e) thinning and (f ) thickness distributions on a typical final part
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Methodology used to predict coefficient of friction based on measurement values and FEA results



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