Improving the Reliability of the Tube-Hydroforming Process by the Taguchi Method

[+] 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

T. J. Nye

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

Don R. Metzger

Reactor Engineering Services Department, Atomic Energy of Canada Limited, 12251 Speakman Drive, Mississauga, Ontario, L5K 1B2 Canadametzgerd@aecl.ca

J. Pressure Vessel Technol 129(2), 242-247 (May 21, 2006) (6 pages) doi:10.1115/1.2716427 History: Received January 24, 2006; Revised May 21, 2006

The tube-hydroforming process has undergone extremely rapid development. To ensure a reliable hydroforming process at the design stage, applying robust design methodologies becomes crucial to the success of the resulting process. The reliability of the tube-hydroforming process based on the tube wall thickness thinning ratio is studied in this paper. In order to improve the reliability of the process, the Taguchi method, which is capable of evaluating the effects of process variables on both the mean and variance of process output, is used to determine the optimal forming parameters for minimizing the variation and average value of the thinning ratio. Finite element simulation is used to analyze the virtual experiments according to the experimental arrays. A cross-extrusion hydroformed tube is employed as an example to illustrate the effectiveness of this approach.

Copyright © 2007 by American Society of Mechanical Engineers
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Figure 8

Reliability of the process with the initial and optimal forming parameters

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Figure 1

Resulting thinning ratio–limit thinning ratio interference model

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Figure 2

Schematic view of the tube-hydroforming process

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Figure 3

Finite element mesh and effective strain contour

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Figure 4

Mean values of thinning ratio for each design parameter

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Figure 5

Standard deviation of thinning ratio for each design parameter

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Figure 6

S/N ratio graph for the thinning ratio

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Figure 7

Interaction analysis of parameters A and B




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