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Enhancement on plastic deformation of curved surface shell by sheet hydroforming with optimized pre-bulging process

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Abstract

For sheet metal components, the enhancement of formability during plastic deformation is a key criterion in the evaluation of forming quality. To realize homogenous deformation during the forming of curved surface shells, a pre-bulging process combined with sheet hydroforming technology was designed. The pre-bulging shape was optimized using response surface methodology. An experimental setup was manufactured to conduct pre-bulging and sheet hydroforming process. The distribution of strain and thickness were measured to present the formability of the parts. The stress distribution was calculated to analyze the deformation mechanism. Results show that when using appropriate pre-bulging and sheet hydroforming process, the average strain value and uniform deformation parameter can be improved simultaneously. The microhardness of formed shell is increased. The stress state in the center region after pre-bulging is changed to biaxial compression state. It can be concluded that the combination between optimized pre-bulging effect and sheet hydroforming process is a potential method for the enhancement of formability including deformation value and uniformity.

Optimization results of pre-bulging parameters (a), sheet hydroforming process after pre-bulging (b), uniform deformation parameter of strain (c), and deformation parameters of thickness (d).

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Funding

This study is supported by The National Key Research and Development Program of China (No. 2017YFB0306304), National Natural Science Foundation of China (No. U1637209), the Fundamental Research Funds for the Central Universities (WUT: 2018III074GX, 2018IVA062 and 2018III067GX) and Natural Science Foundation of Hubei Province, China (Grant No. 2016CFB269).

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Authors and Affiliations

  1. National Key Laboratory for Precision Hot Processing of Metals, Harbin Institute of Technology, Harbin, 150001, China

    Wei Liu, Yong-Chao Xu & Shi-Jian Yuan

  2. School of Materials Science and Engineering, Harbin Institute of Technology, Harbin, 150001, China

    Wei Liu, Yi-Zhe Chen, Yong-Chao Xu & Shi-Jian Yuan

  3. Hubei Key Laboratory of Advanced Technology for Automotive Components, Wuhan University of Technology, Wuhan, 430070, China

    Yi-Zhe Chen

Authors
  1. Wei Liu
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  2. Yi-Zhe Chen
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  3. Yong-Chao Xu
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  4. Shi-Jian Yuan
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Corresponding author

Correspondence to Wei Liu.

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Highlights

• An optimization of pre-bulging shape in sheet hydroforming is conducted.

• The influence of pre-bulging parameters on deformation is discussed.

• The model is verified by experimental works.

• The plastic deformation and forming uniformity are improved simultaneously.

• The stress state during pre-bulging and hydroforming is discussed.

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Liu, W., Chen, YZ., Xu, YC. et al. Enhancement on plastic deformation of curved surface shell by sheet hydroforming with optimized pre-bulging process. Int J Adv Manuf Technol 97, 4145–4156 (2018). https://doi.org/10.1007/s00170-018-2185-5

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  • DOI: https://doi.org/10.1007/s00170-018-2185-5

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