Skip to main content
SpringerLink
Log in

Analytical model of corner filling with granular media to investigate the friction effect between tube and media

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

Abstract

In a tube forming process, granular matter is used as pressure transmission medium instead of liquid to expand a circular tube into one with square section. In this process, the friction at media/tube interface has a significant effect on the final result. In this paper, an analytical model was developed to determine the influence of the friction on the deformation developing process and final thickness distribution along the tube section. Experimental researches were also implemented to evaluate the analytical model in the end. In this model, four friction situations were applied to the numerical analysis process according to the active or negative function of friction on the flow of metal. The analysis result showed that different friction situations could lead to different deformation processes and thickness distributions. The examination on experiments of AA6061 tube indicated that the experimental data of thickness was extremely close to the analysis result with the friction situation in which the metal flow toward the corner of square section die was impeded by the friction force. However, the analytical prediction of thinning trend of thickness had a deviation compared with the experimental data in the corner region. In addition, the breaking and caking of granules in the tube forming process make the friction situation between the tube and media very complex. Therefore, a further research needs to be conducted from the direction of granular matter mechanics and friction mechanism in order to acquire a more explicit result.

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. Bayoumi LS, Attia AS (2009) Determination of the forming tool load in plastic shaping of a round tube into a square tubular section. J Mater Process Technol 209(4):1835–1842. https://doi.org/10.1016/j.jmatprotec.2008.04.047

    Article  Google Scholar 

  2. Barnwal VK, Raghavan R, Tewari A, Narasimhan K, Mishra SK (2017) Effect of microstructure and texture on forming behaviour of AA-6061 aluminium alloy sheet. Mat Sci Eng A-Struct 679:56–65. https://doi.org/10.1016/j.msea.2016.10.027

    Article  Google Scholar 

  3. Hwang YM, Wu RK (2016) Process and loading path design for hydraulic compound forming of rectangular tubes. Int J Adv Manuf Technol 91(5):1–8. https://doi.org/10.1007/s00170-016-9919-z

    Article  Google Scholar 

  4. Jia X, Zhao C (2016) Research and application of weight function in flexible male die drawing deformation mechanism. Int J Adv Manuf Technol 89(5–8):1–16. https://doi.org/10.1007/s00170-016-9182-3

    Article  Google Scholar 

  5. Dong G, Zhao C, Peng Y, Li Y (2015) Hot granules medium pressure forming process of AA7075 conical parts. Chin J Mech Eng 28(3):580–591. https://doi.org/10.3901/CJME.2015.0217.019

    Article  Google Scholar 

  6. Cao M, Zhao C, Dong G, Yang S (2016) Instability analysis of free deformation zone of cylindrical parts based on hot-granule medium-pressure forming technology. Trans Nonferrous Met Soc China 26(8):2188–2196. https://doi.org/10.1016/S1003-6326(16)64335-2

    Article  Google Scholar 

  7. Dong G, Yang Z, Zhao J, Zhao C, Cao M (2016) Stress-strain analysis on AA7075 cylindrical parts during hot granule medium pressure forming. J Cent South Univ 23(11):2845–2857. https://doi.org/10.1007/s11771-016-3348-x

    Article  Google Scholar 

  8. Chen X, Zhao C, Dong G, Yang Z, Cao M (2016) Formability of hot non-metallic granule medium of AA5083 aluminum alloy tube under various loading paths. China Mechanical Engineering (in Chinese). https://doi.org/10.3969/j.issn.1004-132X.2016.18.022

  9. Grüner M, Merklein M (2010) Numerical simulation of hydro forming at elevated temperatures with granular material used as media compared to the real part geometry. Int J Mater Form 3(1):279–282. https://doi.org/10.1007/s12289-010-0761-9

    Article  Google Scholar 

  10. Grüner M, Merklein M (2011) Influences on the molding in hydroforming using granular material as a medium. AIP Conf Proc 1383:645–652. https://doi.org/10.1063/1.3623668

    Article  Google Scholar 

  11. Grüner M, Gnibl T, Merklein M (2014) Blank hydroforming using granular material as medium-investigations on leakage. Procedia Eng. 81:1035–1042. https://doi.org/10.1016/j.proeng.2014.10.137

    Article  Google Scholar 

  12. Chen H, Güner A, Khalifa NB, Tekkaya AE (2016) Granular media-based tube press hardening. J Mater Process Technol 228:145–159. https://doi.org/10.1016/j.jmatprotec.2015.03.028

    Article  Google Scholar 

  13. Kridli GT, Bao L, Mallick PK, Tian Y (2003) Investigation of thickness variation and corner filling in tube hydroforming. J Mater Process Technol 133(3):287–296. https://doi.org/10.1016/S0924-0136(02)01004-X

    Article  Google Scholar 

  14. Zhang WW, Wang XS, Cui XL, Yuan SJ (2015) Analysis of corner filling behavior during tube hydro-forming of rectangular section based on Gurson–Tvergaard–Needleman ductile damage model. Proc IMechE Part B: J Eng Manuf 229(9):1566–1574. https://doi.org/10.1177/0954405414537247

    Article  Google Scholar 

  15. Hwang YM, Chen WC (2005) Analysis of tube hydroforming in a square cross-sectional die. Int J Plast 21(9):1815–1833. https://doi.org/10.1016/j.ijplas.2004.09.004

    Article  MATH  Google Scholar 

  16. Orban H, Hu SJ (2007) Analytical modeling of wall thinning during corner filling in structural tube hydroforming. J Mater Process Technol 194(1–3):7–14. https://doi.org/10.1016/j.jmatprotec.2007.03.112

    Article  Google Scholar 

  17. Abdelkefi A, Guermazi N, Boudeau N, Malécot P, Haddar N (2016) Effect of the lubrication between the tube and the die on the corner filling when hydroforming of different cross-sectional shapes. Int J Adv Manuf Technol 87(1169–1181):1169–1181. https://doi.org/10.1007/s00170-016-8552-1

    Article  Google Scholar 

  18. Abdelkefi A, Malécot P, Boudeau N, Guermazi N, Haddar N (2017) Evaluation of the friction coefficient in tube hydroforming with the “corner filling test” in a square section die. Int J Adv Manuf Technol 88:2265–2273. https://doi.org/10.1007/s00170-016-8945-1

    Article  Google Scholar 

  19. GhorbaniMenghari H, ZiaeiPoor H, Farzin M, Alves De Sousa RJ (2014) An approach to improve thickness distribution and corner filling of copper tubes during hydro-forming processes. Struct Eng Mech 50(4):563–573. https://doi.org/10.12989/sem.2014.50.4.563

    Article  Google Scholar 

  20. Eftekhari Shahri SE, Ahmadi Boroughani SY, Khalili K, Kang BS (2015) Ultrasonic tube hydroforming, a new method to improve formability. Procedia Technol. 19:90–97. https://doi.org/10.1016/j.protcy.2015.02.014

    Article  Google Scholar 

  21. Dong G, Zhao C, Cao M (2013) Flexible-die forming process with solid granule medium on sheet metal. Trans Nonferrous Met Soc China 23(9):2666–2677. https://doi.org/10.1016/S1003-6326(13)62783-1

    Article  Google Scholar 

  22. He Z, Fan X, Shao F, Wang Z, Yuan S (2012) Formability and microstructure of AA6061 Al alloy tube for hot metal gas forming at elevated temperature. Trans Nonferrous Met Soc China 22:s364–s369. https://doi.org/10.1016/S1003-6326(12)61732-4

    Article  Google Scholar 

  23. Seyedkashi SMH, Naeini HM, Moon YH (2014) Feasibility study on optimized process conditions in warm tube hydroforming. J Mech Sci Technol 28(7):2845–2852. https://doi.org/10.1007/s12206-014-0638-9

    Article  Google Scholar 

  24. Khosrojerdi E, Bakhshi-Jooybari M, Gorji A, Hosseinipour SJ (2017) Experimental and numerical analysis of hydrodynamic deep drawing assisted by radial pressure at elevated temperatures. Int J Adv Manuf Technol 88(1–4):185–195. https://doi.org/10.1007/s00170-016-8753-7

    Article  Google Scholar 

  25. Dong GJ, Bi J, Du B, Chen XH, Zhao CC (2017) Research on AA6061 tubular components prepared by combined technology of heat treatment and internal high pressure forming. J Mater Process Technol 242:126–138. https://doi.org/10.1016/j.jmatprotec.2016.11.035

    Article  Google Scholar 

Download references

Funding

The present work is financed by the National Natural Science Foundation of China (contract no. 51605420 and 51775481), the Talent Engineering Project of Heibei Province of China (grant number A2016002017), and the Key Project of Science and Technology Plan of Hebei Higher School of Education Department (grant number ZD2017078). The authors would like express their sincere appreciation to the funds.

Author information

Authors and Affiliations

  1. Key Laboratory of Advanced Forging & Stamping Technology and Science of Ministry of Education, Yanshan University, Qinhuangdao, 066004, China

    Zhuoyun Yang, Changcai Zhao, Bing Du & Li Zhang

  2. Hebei Key Laboratory of Special Delivery Equipment, Yanshan University, Qinhuangdao, 066004, China

    Guojiang Dong

Authors
  1. Zhuoyun Yang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Changcai Zhao
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Guojiang Dong
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Bing Du
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Li Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Changcai Zhao.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Yang, Z., Zhao, C., Dong, G. et al. Analytical model of corner filling with granular media to investigate the friction effect between tube and media. Int J Adv Manuf Technol 99, 211–224 (2018). https://doi.org/10.1007/s00170-018-2429-4

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-018-2429-4

Keywords

Search

Navigation