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A study of techniques in the evaluation of springback and residual stress in hydroforming

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Abstract

The increasing need for high strength complex hollow bodies for automotive application is pushing towards the use of sheet hydroforming techniques in conjunction with high strength steels. Unfortunately high strength steels are characterised by high springback levels. In this paper the springback and residual stresses have been analysed by means of laboratory trials carried out using the double sheet hydroforming technique. The attention has been focused on the upper blank of TRIP800 steel. The analysis has been performed using different approaches: i) characterisation of sample accuracy by means of a 3D coordinate measuring machine using a new proposed method based on the standard deviation calculation; ii) FE-analysis of both hydroforming and springback stages using an implicit FEM code; iii) residual stress evaluation by means of X-ray diffraction and laser cutting techniques. The effect of pressure, die insert geometry and friction at the blank holder on springback and residual stresses have been analysed and discussed in detail.

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Abbreviations

T:

Top of the part

R:

Corner radius of the part

DMRS:

Difference between the inner and the outer mean residual stresses

MeanRSin :

Inner mean residual stresses

MeanRSout :

Outer mean residual stresses

S1:

First set of experimental trials

S2:

Second set of experimental trials

FEC:

Free expansion at the corners

CEC:

Constrained expansion at the corners

ϕ and ψ:

Inclination of the sample for X-ray diffraction technique

OP:

Overpressure evaluated from experimental curves

ɛeq :

Equivalent plastic strain

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Authors and Affiliations

  1. Department of Mechanics, Polytechnic University of Marche, Via Brecce Bianche, I-60131, Ancona, Italy

    C. Bruni & F. Gabrielli

  2. Chair of Manufacturing Technology, University of Erlangen-Nuremberg, Egerlandstraβe 11, D-91058, Erlangen, Germany

    M. Celeghini & M. Geiger

Authors
  1. C. Bruni
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  2. M. Celeghini
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  3. M. Geiger
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  4. F. Gabrielli
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Correspondence to C. Bruni.

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Bruni, C., Celeghini, M., Geiger, M. et al. A study of techniques in the evaluation of springback and residual stress in hydroforming. Int J Adv Manuf Technol 33, 929–939 (2007). https://doi.org/10.1007/s00170-006-0539-x

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  • DOI: https://doi.org/10.1007/s00170-006-0539-x

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