Reliability Analysis of the Tube Hydroforming Process Based on Forming Limit Diagram

[+] Author and Article Information
Bing Li

Operations Engineering Directorate, Nuclear Safety Solutions Limited, 700 University Avenue, 4th Floor, Toronto, Ontario, M5G 1X6, Canadabing.li@nuclearsafetysolutions.com

Don R. Metzger

Reactor Engineering Services Department, Atomic Energy of Canada Limited, 2251 Speakman Drive, Mississauga, Ontario, L5K 1B2, Canadametzgerd@mcmaster.ca

Tim J. Nye

Department of Mechanical Engineering, McMaster University, 1280 Main Street West, Hamilton, Ontario, L8S 4L7, Canadanyet@mcmaster.ca

J. Pressure Vessel Technol 128(3), 402-407 (Jun 28, 2005) (6 pages) doi:10.1115/1.2218344 History: Received March 17, 2003; Revised June 28, 2005

Tube hydroforming is an attractive manufacturing process in the automotive industry because it has several advantages over alternative methods. In order to determine the reliability of the process, a new method to assess the probability of failure is proposed in this paper. The method is based on the reliability theory and the forming limit diagram, which has been extensively used in metal forming as the criteria of formability. From the forming limit band in the forming limit diagram, the reliability of the forming process can be evaluated. A tube hydroforming process of free bulging is then introduced as an example to illustrate the approach. The results show this technique to be an innovative approach to avoid failure during tube hydroforming.

Copyright © 2006 by American Society of Mechanical Engineers
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Figure 3

Concept of nominal strain and nominal limit strain

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Figure 4

Nominal strain—nominal limit strain interference model

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Figure 5

Schematic view of free bulging hydroforming

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Figure 6

Loading path in simulation

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Figure 7

Effect of the different parameters on the bulge height

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Figure 8

Strain distribution of hydroformed tube

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Figure 9

Effective strain contour of hydroformed tube

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Figure 10

Strain distribution of element 3660

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Figure 11

Relationship between nominal strain and the parameters

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Figure 1

Example of forming limit diagram

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Figure 2

Forming limit band in FLD




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