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Numerical and experimental investigation of the effect of double-sided hydroforming process on wrinkling damage by optimizing loading curves with adaptive control

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Abstract

In this study, by using the double-sided hydroforming process (DSHP), scientific studies have been conducted to reach the highest formability possible with today’s technology in deep drawing at room temperature and to produce difficult-to-shape parts. For the first time, the type-2 fuzzy logic controller (T2FLC) working with adaptive finite element analysis (aFEA) was applied to the DSHP, with the expectation that it would be a satisfactory solution to problems such as wrinkling, especially in the production of parts with different cross sections in the direction of the axis. In the literature, no study was found in which adaptive finite element analysis (aFEA) integrated with fuzzy logic control algorithms and genetic algorithm was applied to the DSHP to obtain the optimum back pressure profile. T2FLC was developed for the conical workpiece, and the variables used in the cylindrical workpiece were used first. DSHP is modeled with finite element method, and fuzzy logic algorithms have been developed to provide adaptive control in analyses. Using the aFEA-FLC optimum loading profiles also internal pressures and blank holder force loading profiles were determined. DSHP experiments were performed by the optimum loading profiles, and manufactured part geometry was compared with the part manufactured by non-applied back pressure in the sheet hydroforming process. By using the loading profiles obtained sheet metal parts have been successfully shaped numerically and experimentally without wrinkling or any other damage. It has been observed that as soon as the back pressure is applied, the wrinkling disappears, and the parts can be formed completely. It was concluded that DSHP is more effective than other hydroforming methods in terms of preventing wrinkling in axisymmetric parts with variable cross section.

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Acknowledgements

This work has been extracted from Selahattin Burak Akay’s Ph.D. thesis.

Funding

This article was supported by the Scientific and Technological Research Council of Turkey (TUBITAK) (grant number 217M700).

Author information

Authors and Affiliations

  1. Technical Sciences Vocational School of Higher Education, Konya Technical University, Konya, Turkey

    Selahattin Burak Akay

  2. Department of Mechanical Engineering, Konya Technical University, Konya, Turkey

    Hüseyin Selçuk Halkacı, Osman Öztürk, Mevlüt Aydın & Mevlüt Türköz

  3. Department of Mechanical Eng., Seydisehir Ahmet Cengiz Faculty of Eng., Necmettin Erbakan University, Konya, Turkey

    Ekrem Öztürk

  4. Department of Mechanical Engineering, Faculty of Engineering, Tarsus University, Mersin, Turkey

    Gürkan Ataş

  5. Department of Mechanical Engineering, Faculty of Engineering, Necmettin Erbakan University, Konya, Turkey

    Murat Dilmeç

Authors
  1. Selahattin Burak Akay
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  2. Hüseyin Selçuk Halkacı
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  3. Ekrem Öztürk
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  4. Osman Öztürk
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  5. Gürkan Ataş
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  6. Mevlüt Aydın
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  7. Mevlüt Türköz
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  8. Murat Dilmeç
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Contributions

SBA: methodology, investigation, experimental and numerical study, review, and editing. HSH: funding acquisition, conceptualization, methodology. EÖ: investigation, experimental study, writing, and editing. OÖ: investigation, experimental study, writing, and editing. GA: investigation, experimental study. MA: investigation, experimental study. MT: methodology, investigation, experimental and numerical study, review, and editing. MD: methodology, investigation, writing—review, and editing.

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Correspondence to Murat Dilmeç.

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Akay, S.B., Halkacı, H.S., Öztürk, E. et al. Numerical and experimental investigation of the effect of double-sided hydroforming process on wrinkling damage by optimizing loading curves with adaptive control. Int J Adv Manuf Technol 121, 2149–2168 (2022). https://doi.org/10.1007/s00170-022-09467-8

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  • DOI: https://doi.org/10.1007/s00170-022-09467-8

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