Skip to main content
SpringerLink
Log in

The effect of tube bending, heat treatment and loading paths on process responses of hydroforming for automobile intercooler pipe: numerical and experimental investigations

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

This study was carried out to investigate the effect of preliminary processes on tube hydroforming (THF) and to optimize the THF process parameters to achieve a sound complex 3D curved intercooler pipe without failure by numerical and experimental approaches. The effect of three-step rotary bending on the thickness distribution and microstructure of the tube has been evaluated. The necessity of heat treatment is analyzed prior to the THF process. The stroke of punches should be optimized separately according to the asymmetry geometry characteristics of the intercooler pipe. The suitable loading path is discussed during the THF process. The results obtained from simulation keep a reasonable agreement with that from the experiment.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Zhang SH (1999) Developments in hydroforming. J Mater Process Technol 91:236–244

    Article  Google Scholar 

  2. Dohmann F, Hartl C (1996) Hydroforming—a method to manufacture light-weight parts. J Mater Process Technol 60:669–676

    Article  Google Scholar 

  3. Xu Y, Zhang SH, Cheng M, Song HW (2015) Formability improvement of austenitic stainless steel by pulsating hydroforming. Proc IMechE, Part B: J Engineering Manufacture 229:609–615

    Article  Google Scholar 

  4. Ahmetoglu M, Altan T (2000) Tube hydroforming: state-of-the-art and future trends. J Mater Process Technol 98:25–33

    Article  Google Scholar 

  5. Uysal A, Ozalp AA, Korgavus A, Korgavus O (2012) Numerical modeling of the momentum and thermal characteristics of air flow in the intercooler connection hose. Int J Adv Manuf Technol 60:811–824

    Article  Google Scholar 

  6. Gao L, Strano M (2004) FEM analysis of tube pre-bending and hydroforming. J Mater Process Technol 151:294–297

    Article  Google Scholar 

  7. Yang JB, Jeon BH, Oh SI (2001) The tube bending technology of a hydroforming process for an automotive part. J Mater Process Technol 111:175–181

    Article  Google Scholar 

  8. Trana K (2002) Finite element simulation of the tube hydroforming process—bending, preforming and hydroforming. J Mater Process Technol 127:401–408

    Article  Google Scholar 

  9. Bihamta R, Bui QH, Guillot M, D’Amours G, Rahem A, Fafard M (2015) Global optimisation of the production of complex aluminium tubes by the hydroforming process. CIRP J Manuf Sci Technol 9:1–11

    Article  Google Scholar 

  10. Guo XZ, Liu Z, Wang H, Wang L, Ma F, Sun X, Tao J (2016) Hydroforming simulation and experiment of clad T-shapes. Int J Adv Manuf Technol 83:381–387

    Article  Google Scholar 

  11. Xu Y, Ma Y, Zhang SH, Chen DY, Zhang XS, Li JM, Zhao ZJ (2016) Numerical and experimental study on large deformation of thin-walled tube through hydroforging process. Int J Adv Manuf Technol 87:1885–1890

    Article  Google Scholar 

  12. ETA (2011) eta/Dynaform user’s manual

  13. Kadkhodayan M, Erfani-Moghadam A (2012) An investigation of the optimal load paths for the hydroforming of T-shaped tubes. Int J Adv Manuf Technol 61:73–85

    Article  Google Scholar 

  14. Yang B, Zhang WG, Li SH (2006) Analysis and finite element simulation of the tube bulge hydroforming process. Int J Adv Manuf Technol 29:453–458

    Article  Google Scholar 

  15. Parsa MH, Ahkami AL (2008) Bending of work hardening sheet metals subjected to tension. Int J Mater Form Suppl 1:173–176

    Article  Google Scholar 

  16. Chen X, Chen X, Xu H, Madigan B (2015) Monte Carlo simulation and experimental measurements of grain growth in the heat affected zone of 304 stainless steel during multipass welding. Int J Adv Manuf Technol 80:1197–1211

    Article  Google Scholar 

  17. Yan L, Yang W, Jin H, Wang Z (2012) Analytical modelling of microstructure changes in the machining of 304 stainless steel. Int J Adv Manuf Technol 58:45–55

    Article  Google Scholar 

  18. Xu Y, Zhang SH, Cheng M, Song HW (2012) In situ X-ray diffraction study of martensitic transformation in austenitic stainless steel during cyclic tensile loading and unloading. Scripta Mater 67:771–774

    Article  Google Scholar 

  19. Xu Y, Zhang SH, Song HW, Cheng M, Zhang H (2011) The enhancement of transformation induced plasticity effect on austenitic stainless steels by cyclic tensile loading and unloading. Mater Lett 65:1545–1547

    Article  Google Scholar 

  20. Guo XZ, Liu H, Cui S, Liu Z, Tao J (2014) Investigation on the maximum thinning and protrusion height of the hydroformed 316L SS/Al clad T-branch. Int J Adv Manuf Technol 73:727–733

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Dalian University of Technology, Dalian, 116024, China

    Yan Ma & Guoqing Chen

  2. Institute of Metal Research, Chinese Academy of Sciences, Shenyang, 110016, China

    Yan Ma, Yong Xu, Shihong Zhang, Dayong Chen & Ali Abd El-Aty

  3. Henan Xingdi Forging Equipment Manufacturing Co., Ltd., Xinxiang, 453600, China

    Jingming Li & Zhangjian Zhao

Authors
  1. Yan Ma
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yong Xu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Shihong Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Dayong Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Ali Abd El-Aty
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Jingming Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Zhangjian Zhao
    View author publications

    You can also search for this author in PubMed Google Scholar

  8. Guoqing Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Yong Xu.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Ma, Y., Xu, Y., Zhang, S. et al. The effect of tube bending, heat treatment and loading paths on process responses of hydroforming for automobile intercooler pipe: numerical and experimental investigations. Int J Adv Manuf Technol 91, 2369–2381 (2017). https://doi.org/10.1007/s00170-016-9920-6

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-016-9920-6

Keywords

Search

Navigation