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Research Papers

Investigation of Forming Cylindrical Parts in a Modified Hydrodynamic Deep Drawing Assisted by Radial Pressure With Inward Flowing Liquid

[+] Author and Article Information
Milad Sadegh Yazdi

Department of Mechanical Engineering,
Advanced Material Forming Research Center,
Babol Noshirvani University of Technology,
Babol 48187-1167, Iran
e-mail: mi.sadeghi@stu.nit.ac.ir

Mohammad Bakhshi-Jooybari

Professor
Department of Mechanical Engineering,
Advanced Material Forming Research Center,
Babol Noshirvani University of Technology,
Babol 48187-1167, Iran
e-mail: bakhshi@nit.ac.ir

Hamid Gorji

Department of Mechanical Engineering,
Advanced Material Forming Research Center,
Babol Noshirvani University of Technology,
Babol 48187-1167, Iran
e-mail: hamidgorji@nit.ac.ir

Mohsen Shakeri

Professor
Department of Mechanical Engineering,
Fuel Cell Research Center,
Babol Noshirvani University of Technology,
Babol 48187-1167, Iran
e-mail: Shakeri@nit.ac.ir

Maziar Khademi

Mem. ASME
Department of Mechanical Engineering,
Advanced Material Forming Research Center,
Babol Noshirvani University of Technology,
Babol 48187-1167, Iran
e-mail: m.khademi@stu.nit.ac.ir

1Corresponding author.

Manuscript received June 1, 2017; final manuscript received November 6, 2017; published online December 21, 2017. Assoc. Editor: Gracious Ngaile.

J. Manuf. Sci. Eng 140(3), 031007 (Dec 21, 2017) (9 pages) Paper No: MANU-17-1350; doi: 10.1115/1.4038512 History: Received June 01, 2017; Revised November 06, 2017

Among the sheet hydroforming processes, hydrodynamic deep drawing (HDD) process has been used to form complex shapes and can produce parts with high drawing ratio. Studies showed that radial pressure created on the edge of the sheet can decrease the drawing force and increase drawing ratio. Thus, increasing of radial pressure to an amount greater than chamber pressure, and independent control of these pressures, is the basic idea in this study. In this research, the effect of radial and chamber pressures on formability of St13 and pure copper sheets in the process of hydrodynamic deep drawing assisted by radial pressure (HDDRP) with inward flowing liquid is investigated. Giving that a significant portion of the maximum thinning of the formed part occurs in the beginning of the process, the pressure supply system used in the experimental tests was designed in a way, which provides simultaneous control of the radial and chamber pressures throughout the process. Thickness distribution, forming force, and tensile stresses are the parameters that were evaluated in this study. Results indicated that using a higher radial pressure than the chamber pressure and controlling their values in the initial stages of the process enhances the thickness distribution of the formed part in all regions. A comparison between the thickness distribution and maximum forming force of the formed parts by the HDDRP and HDDRP with inward flowing liquid methods showed that by applying the later method, parts with more uniform thickness distribution and less maximum thinning and forming force can be achieved.

Copyright © 2018 by ASME
Topics: Pressure , Simulation , Copper
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References

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Figures

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Fig. 1

Schematic illustration of the die set in the HDDRP process with inward flowing liquid [9]

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Fig. 2

Schematic of the die set used and the main parameters

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Fig. 3

(a) Components of the die set: 1—punch, 2—blank holder, 3—die, 4—pressure gauge, and 5—testing machine. (b) Schematic of the die set and pressure system [15].

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Fig. 4

The typical radial and chamber pressures versus punch displacement

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Fig. 5

(a) The assembled finite element model and (b) the finite element model of the die components

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Fig. 6

(a) Comparison of kinetic energy and internal energy and (b) kinetic energy of the entire model

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Fig. 7

Formed cups (a) St13 sheet at stroke of 29.5 mm and (b) pure copper sheet at stroke of 38 mm, obtained from experiments and simulations at maximum cavity and radial pressures of 26 and 48 MPa, respectively

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Fig. 8

Sectional view of the formed part (a) St13 at stroke of 29.5 mm and (b) pure copper at stroke of 38 mm at maximum cavity and radial pressures of 26 and 48 MPa, respectively

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Fig. 9

Thickness distribution curve at stroke of 29.5 mm, (b) punch force-stroke, for St13 cups at maximum cavity and radial pressures of 26 and 48 MPa, respectively

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Fig. 10

Thickness distribution curve at stroke of 38 mm, (b) punch force-stroke, for pure copper cup at maximum cavity and radial pressures of 26 and 48 MPa, respectively

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Fig. 11

Thickness distribution curves of formed St13 parts with different chamber pressures; radial pressure, 45 MPa; punch stroke, 41 mm

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Fig. 12

Thickness distribution curves of St13 specimens at different radial pressure paths, maximum chamber pressure, 15 MPa

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Fig. 13

(a) Selected paths for investigation of radial stresses in the formed cylindrical cups of St13, (b) radial stress with respect to distance from center of the part along path (1), and (c) radial stress with respect to distance from center of the part along path (2), Pc max = 15 MPa

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Fig. 14

Punch force-stroke curves of St13 specimens at different radial pressure paths, maximum chamber pressure, 15 MPa

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Fig. 15

Desired pressure paths, (b) variation of minimum thickness versus maximum pressure for St13 cups, in HDDRP process

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Fig. 16

(a) Comparison of thickness distribution curve and (b) punch force-stroke, for St13 cups formed in HDDRP and HDDRP with inward flowing liquid processes

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Fig. 17

Comparison of thickness distribution curve for pure copper cups (a) different radial pressure paths at constant chamber pressure of 10 MPa and (b) different chamber pressure paths at constant radial pressure of 40 MPa

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