Research Papers

Real-Time Friction Error Compensation in Tube Hydroforming Process Control

[+] Author and Article Information
Gracious Ngaile, Chen Yang, Obadiah Kilonzo

Department of Mechanical and Aerospace Engineering,  North Carolina State University, Raleigh, NC 27695

J. Manuf. Sci. Eng 133(6), 061028 (Dec 27, 2011) (10 pages) doi:10.1115/1.4005430 History: Received September 01, 2010; Accepted October 31, 2011; Published December 27, 2011; Online December 27, 2011

Tube hydroforming (THF) is a metal-forming process that uses a pressurized fluid in place of a hard tool to plastically deform a given tube into a desired shape. In addition to the internal pressure, the tube material is fed axially toward the die cavity. One of the challenges in THF is the nonlinear and varying friction conditions at the tube-tool interface, which make it difficult to establish accurate loading paths (pressure versus feed) for THF. A THF process control model that can compensate for the loading path deviation due to frictional errors in tube hydroforming is proposed. In the proposed model, an algorithm and a software platform have been developed such that the sensed forming load from a THF machine is mapped to a database containing a set of loading paths that correspond to different friction conditions for a specific part. A real-time friction error compensation is then carried out by readjusting the loading path as the THF process progresses. This scheme reduces part failures that would normally occur due to variability in friction conditions. The implementation and experimental verification of the proposed model is discussed.

Copyright © 2011 by American Society of Mechanical Engineers
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Figure 1

Tube size and material properties for DOE simulation matrix

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Figure 2

Forming pressure at axial feed used in the Y-shape simulation

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Figure 3

Contribution ratio of the uncertainty variables to the deviation of axial forming load

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Figure 4

Effect of friction on the loading path: (a and b) single-Y shape, (c and d) double-Y shape, (e and f) double-T shape

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Figure 5

Thinning distribution of the hydroformed Y-shape under different friction conditions

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Figure 6

Database back-step scheme

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Figure 7

Loading path database

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Figure 8

Flow chart of DBS algorithm

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Figure 9

Equipment for the THF process

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Figure 10

System integration scheme of error compensation realization

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Figure 11

Experimental set-up

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Figure 12

Split dies and hydroformed double-T and double-Y shapes

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Figure 13

Input pressure and output pressure from the hydroforming machine

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Figure 14

Comparison of punch loads from the database and those obtained from experiment for different lubrication conditions

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Figure 15

Nonlinear friction characteristic for different lubrication conditions

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Figure 16

Nonlinear friction characteristic for different lubrication conditions



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