0
Design Innovation Paper

Design, Fabrication, and Experimental Validation of a Warm Hydroforming Test System

[+] Author and Article Information
Mevlüt Türköz

Department of Mechanical Engineering,
Faculty of Engineering,
Selcuk University,
Konya 42075, Turkey
e-mail: mevlutturkoz@selcuk.edu.tr

Hüseyin Selçuk Halkacı

Department of Mechanical Engineering,
Faculty of Engineering,
Selcuk University,
Konya, Turkey

Mehmet Halkacı

Technical Sciences Vocational School of Higher Education,
Selcuk University,
Konya, Turkey

Murat Dilmeç

Department of Mechanical Engineering,
Faculty of Engineering and Architecture,
Necmettin Erbakan University,
Konya, Turkey

Semih Avcı

Institute of the Natural and Applied Sciences,
Selcuk University,
Campus of Alaeddin Keykubat,
Konya 42250, Turkey

Muammer Koç

Department of Materials Science and Engineering, Gaziantep University,
Gaziantep, Turkey;
Sustainability Division,
College of Science and Engineering (CSE),
Qatar Energy and Environment Research Institute (QEERI),
HBKU,
Qatar Foundation (QF),
Education City (EC),
Doha, Qatar

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received June 23, 2015; final manuscript received August 21, 2015; published online October 27, 2015. Assoc. Editor: Gracious Ngaile.

J. Manuf. Sci. Eng 138(4), 045001 (Oct 27, 2015) (15 pages) Paper No: MANU-15-1306; doi: 10.1115/1.4031498 History: Received June 23, 2015; Revised August 21, 2015

In this study, a hydroforming system was designed, built, and experimentally validated to perform lab-scale warm hydromechanical deep drawing (WHDD) tests and small-scale industrial production with all necessary heating, cooling, control and sealing systems. This manuscript describes the detailed design and fabrication stages of a warm hydroforming test and production system for the first time. In addition, performance of each subsystem is validated through repeated production and/or test runs as well as through part quality measurements. The sealing at high temperatures, the proper insulation and isolation of the press frame from the tooling and synchronized control had to be overcome. Furthermore, in the designed system, the flange area can be heated up to 400 °C using induction heaters in the die and blank holders (BH), whereas the punch can be cooled down to temperatures of around 10 °C. Validation and performance tests were performed to characterize the capacity and limits of the system. As a result of these tests, the fluid pressure, the blank holder force (BHF), the punch position and speed were fine-tuned independent of each other and the desired temperature distribution on the sheet metal was obtained by the heating and cooling systems. Thus, an expanded optimal process window was obtained to enable all or either of increased production/test speed, reduced energy usage and time. Consequently, this study is expected to provide other researchers and manufacturers with a set of design and process guidelines to develop similar systems.

Copyright © 2016 by ASME
Your Session has timed out. Please sign back in to continue.

References

Figures

Grahic Jump Location
Fig. 1

The warm hydroforming press

Grahic Jump Location
Fig. 2

WHDD tooling design

Grahic Jump Location
Fig. 3

Schematic of the heating and cooling systems designed for WHDD unit

Grahic Jump Location
Fig. 4

Locations of the thermocouples on the die and BH

Grahic Jump Location
Fig. 5

Design of the punch and cooling channels

Grahic Jump Location
Fig. 6

Providing radial sealing with C-ring

Grahic Jump Location
Fig. 7

Force equilibrium in hydromechanical deep drawing process

Grahic Jump Location
Fig. 8

Pressure-leakage force values

Grahic Jump Location
Fig. 9

Die design with axial sealing element: (a) detailed view and (b) general assembly view

Grahic Jump Location
Fig. 10

The average temperature values obtained from eight thermocouples at eight different locations

Grahic Jump Location
Fig. 11

The temperature distribution in the tools during forming at 300 °C

Grahic Jump Location
Fig. 12

Changing of the tool innermost mean temperature at different temperatures during forming process

Grahic Jump Location
Fig. 13

Location of the thermocouples on the fixture

Grahic Jump Location
Fig. 14

Comparison of the sheet and the die outside and inside temperatures for mean temperature (T1–T2) for 300 °C

Grahic Jump Location
Fig. 15

Comparison of the sheet and the die inside and outside temperatures after reaching the target temperature mean temperature (T1–T2) for 300 °C

Grahic Jump Location
Fig. 16

Maximum temperature difference on the sheet during the process for 300 °C

Grahic Jump Location
Fig. 17

Cooling performance of the punch during the process

Grahic Jump Location
Fig. 18

The fluid pressure and BHF profiles obtained in a WHDD experiment

Grahic Jump Location
Fig. 19

The loading profiles in the case studies experiments

Grahic Jump Location
Fig. 20

Measured fluid pressure and BHF values in case 1 experiments

Grahic Jump Location
Fig. 21

Temperature change of thermocouples, which are 10 mm outer than inner ones through the process

Grahic Jump Location
Fig. 22

Changing of the punch temperature during the process

Grahic Jump Location
Fig. 23

Formed cups in the conditions of Case 1 and Case 2

Grahic Jump Location
Fig. 24

Thickness distribution of the cups in RD and TD in Case 1 experiments

Tables

Errata

Discussions

Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In