Finite Element Simulation & Experimental Study on Forming of Conical Parts by HDDRP: Process Window Diagram

Authors

1 Shahid Rajaee Teacher Training University

2 University of Birjand

Abstract

Wrinkling and rupturing are major defects in forming of conical cups. Among the forming processes for producing conical parts with high drawing ratio in one stage, hydrodynamic deep drawing assisted by radial pressure (HDDRP) is a highly reliable method. This method has some advantages compared to conventional deep drawing such as more appropriate thickness distribution, better surface quality, higher limit drawing ratio, higher dimensional accuracy and ability of forming complex parts. In this paper, process window diagram of HDDRP on forming of conical parts was obtained considering several parameters including pressure path, initial thickness and material of the blank, by finite element method. FEM results were validated by experimental tests. The results show that the obtained process window diagram can predict appropriate forming area, and possibility of wrinkling and rupturing occurance with different pressure paths. Comparison of Simulations with experimental parts shows suitable conformity. The results can provide an applicable guidlines for sound hydroforming of conical products in automotive and aerospace industries.

Keywords

Main Subjects

References

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Journal of Solid and Fluid Mechanics
Volume 5, Issue 4 - Serial Number 4
January and February 2016
Pages 139-150

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