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Thinning analysis for hot forming of single-piece hemispherical dish end using finite element simulation and its empirical modeling

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Abstract

Hot forming is an important forming method for production of small and medium sized single-piece pressure vessel dish ends. Thinning of the blank material with increased degree of forming is quite obvious. Present work shows finite element (FE) analysis of hot forming of single-piece hemispherical dish end (SPHDE) for predicting maximum thinning of blank during forming. Thinning analysis is performed for SPHDE of two different ferrous material grades SA-387 Gr22 and SA-516 as per ASME, Section II, Part A (2004). Percentage thinning results of FE analysis are verified with the practical material thinning data. Based on the thinning analysis, empirical relation for calculation of percentage thinning as a function of different dish ends′ geometry parameters is proposed. Empirically predicted percentage thinning is observed to be in good agreement with practical and FE simulation results. Thinning results obtained based on proposed FE simulation and empirical model can be helpful to design engineer in selecting thickness of developed blank considering thinning allowance for hot forming of SPHDE. Thinning analysis data can be used for optimizing the dish end geometrical parameters for minimum thinning during forming.

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Abbreviations

D:

Diameter of dish end (mm)

E:

Young’s moduslus (MPa)

H:

Height of dish end (mm)

Hf :

Flange height of dish end (mm)

K:

Strength coefficient (MPa)

n:

Strain hardening exponent

t:

Minimum thickness of dish end (mm)

T:

Nominal blank thickness (mm)

tp :

Percentage thinning

TS:

Ultimate tensile strength (MPa)

YS:

Yield strength (MPa)

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Acknowledgements

Authors’ appreciate and acknowledge the technical support provided by M/s. Larsen & Toubro Ltd., Hazira Works, Surat, Gujarat, India and M/s. Hiralal Dish End Pvt.Ltd., Pune, Maharastra, India for practical data collection.

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Authors and Affiliations

  1. Mechanical Engineering Department, S. V. National Institute of Technology, Surat, 395007, Gujarat, India

    Harit K. Raval, Harshit K. Dave & Yogesh K. Srivastav

  2. Mechanical Engineering Department, C. K. Pithawalla College of Engineering and Technology, Surat, 395007, Gujarat, India

    Anish H. Gandhi

  3. LEMF, Larsen & Toubro Limited, Hazira Works, Surat, 394510, Gujarat, India

    Mukesh M. Makwana

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  1. Harit K. Raval
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  2. Anish H. Gandhi
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  3. Mukesh M. Makwana
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  4. Harshit K. Dave
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  5. Yogesh K. Srivastav
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Correspondence to Anish H. Gandhi.

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Raval, H.K., Gandhi, A.H., Makwana, M.M. et al. Thinning analysis for hot forming of single-piece hemispherical dish end using finite element simulation and its empirical modeling. Int J Mater Form 6, 115–124 (2013). https://doi.org/10.1007/s12289-011-1078-z

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  • DOI: https://doi.org/10.1007/s12289-011-1078-z

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