• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2001.05a
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• pp.49-53
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• 2001

Recently hydroforming process became a process which is increasingly applied in the automotive industry. As the hydroforming process is a new technology, there is no abundant data to assist manufacturing the products. To investigate the effects of process parameters on the tube hydroforming process, simple bulging, circular bulging and Tee-fitting tests are performed. The optimal leading path to escape the failure modes(bursting, wrinkling) is determined and the effects of the process parameters, the internal pressure and axial feeding on the product quality, such as thickness distribution, forming height and branch dome shape are investigated.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2006.05a
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• pp.226-229
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• 2006

Process design has been performed for the warm hydroforming of light weight alloy tubes. For the heating of tubes, specially designed induction heating system has been adopted to ensure rapid heating of tubes. The induction heating system uses 30kHz frequency induction coil in order to concentrate the energy in the tube and prevent the energy loss. But the induced heat by the integrated heating system, consisting of induction coil, tube, pressure oil and dies, was normally not equally distributed over the length and circumference of the tube specimen, and consequent temperature distribution was non-uniform. So additional heating element has been inserted into the inside of the tube to maintain the forming temperature and reduce temperature drop due to heat loss to the molds. And for that heat loss, a heat insulation system has also been installed. The drop in flow stress at elevated temperatures results in lower internal pressure for hydroforming and lower clamping forces. The proposed warm hydroforming process has been successfully implemented when applying 6061 aluminum extruded tubes.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.10a
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• pp.358-358
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• 2008

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.05a
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• pp.324-324
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• 2008

• Transactions of Materials Processing
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• v.13 no.7
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• pp.629-634
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• 2004

Based on plastic instability, analytical prediction of bursting failure on tube hydroforming processes under combined infernal pressure and independent axial feeding is carried out. Bursting is irrecoverable phenomenon due to local instability under excessive tensile stresses. In order to predict the bursting failure, three different classical necking criteria such as diffuse necking criterion for sheet and tube, local necking criterion for sheet are introduced. The incremental theory of plasticity for anisotropic material is adopted and then the hydroforming limit and bursting failure diagram with respect to axial feeding and hydraulic pressure are presented. In addition, the influences of the material properties such as anisotropy Parameter, strain hardening exponent and strength coefficient on bursting Pressure are investigated. As results of the above approach, the hydroforming limit in view of bursting failure is verified with experimental results.

• Proceedings of the KSME Conference
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• 2000.11a
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• pp.783-788
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• 2000

Hydroforming is a method for forming circular tubes. If this technology is to be applied economically, it is essential to have knowledge of the avoidance of failure cases as well as of the behavior of the tube in the tool under the compressive stress and forces that are exerted by the machine. A finite element simulation for manufacturing of lower arm from straight tubes, using the hydroforming method, was performed to investigate the effects of varying process parameters. Explicit method is used to simulate hydroforming in many cases, but that is not included flow rule. And then it needs simulation for implicit method. It was simulated by two methods, implicit and explicit, to compare the result of the hydroforming.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2001.05a
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• pp.54-58
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• 2001

In recent years, hydroforming technology has been one of the most important technology in automotive industry in the points of weight saving, cost reduction and qualify improvement. However, compared with traditional metal forming technology, hydroforming has much fewer information in experience and empirical knowledge. But we don't have my sufficient time and money to produce hydroforming products using real blank directly Therefore Simulation is essential in hydrofonrung technology development. In this paper, we simulate the side member as the tubular hydroforming technology. The manufacturing process of side member' consists of pre_bending, pre_forming, and hydroforming of a thin tube. Variables such as internal pressure, end feeding, and tool geometry are optimized to improve the forming safety. And we simulate side member according to several lubricant conditions. from those simulations, we find that strain distributions can be reduced well by internal pressure and end feeding control, and lubrication is the most important thing in hydroforming process.

• Transactions of Materials Processing
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• v.14 no.6 s.78
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• pp.527-532
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• 2005

Among the failure modes which can occur in tube hydroforming such as wrinkling, bursting or buckling, the bursting by local instability under excessive tensile stresses is irrecoverable phenomenon. Thus, the accurate prediction of bursting condition plays an important role in producing the successfully hydroformed part without any defects. As the classical forming limit criteria, strain-based forming limit diagram (FLD) has widely used to predict the failure in sheet metal forming. However, it is known that the FLD is extremely dependant on strain path throughout the forming process. Furthermore, The application of FLD to hydroforming process, where strain path is no longer linear throughout forming process, may lead to misunderstanding for fracture initiation. In this work, stress-based forming limit diagram (FLSD), which is strain path-independent and more general, was applied to prediction of forming limit in tube hydroforming. Combined with the analytical FLSD determined from plastic instability theory, finite element analyses were carried out to find out the state of stresses during hydroforming operation, and then FLSD is utilized as forming limit criterion. In addition, the approach is verified by a series of bulge tests in view of bursting pressure and shows a good agreement. Consequently, it is shown that the approach proposed in this paper will provide a feasible method to satisfy the increasing practical demands for judging the forming severity in hydroforming processes.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.145-147
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• 2009

The benefits of hydroforming technology are known as weight and cost savings through part consolidation and reduced post-forming processes such as welding and piercing. Hydroforming technology has some weaknesses in terms of process cycle times. But, as the hydraulic system and process designs are continuously developed, the cycle time is also reduced to acceptable and competitive levels. Hot air bulging is one of recently developed hydroforming techniques. Hot air bulging in order to further extend the forming degrees of Al lightweight material is investigated. A heated tube is placed in a heated die and sealed at the ends by sealing cylinders. The tube is subsequently expanded against the die cavity wall by internal pressure provided by air medium. The result of this study shows that axial feeding speed and air pressure have an effect on formability of Al air bulging at elevated temperature.

• Transactions of Materials Processing
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• v.11 no.4
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• pp.302-311
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• 2002

A generalized numerical approach based on the finite element method to analysis and design of hydroforming process is proposed in this paper. The special attention is focused on comparison of an implicit and an explicit finite element method widely used for hydroforming simulation. Furthermore, in order to meet the increasing real needs for prediction of forming limit, a ductile fracture criterion combined with finite element method is introduced and then applied to hydroforming process of an automobile lower m Consequently, the numerical analysis and design for hydroforming process presented here will facilitate the development and application of the tube hydrofoniung process to a new level.