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Dynamic Frictional Characteristics of TP2 Copper Tubes during Hydroforming under Different Loading and Fluid Velocities

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Abstract

Tube hydroforming (THF) experiments were performed on TP2 copper tubes under different loading velocities and fluid velocities using a self-developed measurement system to investigate dynamic frictional characteristics in the guiding zone. The results show that the coefficient of friction (COF) dynamically changes during forming experiments and decreases with tube deformation. The average descending rate and amplitude of the COF increase with increasing loading velocity. Microscopically, the micro-protrusions on the tubular surface are flattened, and the surface scratches are finer and more uniform, as the loading velocity increases, resulting in a decrease in COF. At the same external loading velocity, the COF increases with increasing fluid velocity and is also extremely sensitive to it. Moreover, improving and predicting the formability of such tubes by accurately adjusting and controlling fluid velocity in THF is valuable and critical for the future.

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Abbreviations

l 0 :

Initial tubular length [mm], Fig. 1

Fig. 1
figure 1

Schematic diagram of the internal fluid mechanics in the guiding zone of the TP2 copper tube

Full size image
l g :

Initial guiding zone length [mm], Fig. 1

l b :

Initial forming zone length [mm], Fig. 1

D 0 :

Initial tubular outer diameter [mm], Fig. 1

t 0 :

Initial tubular thickness [mm], Fig. 1

A :

Cross-sectional area of the fluid or tube [mm2], Eq 2

r, R :

Maximum and minimum radii of the cylinder fluid [mm], Eq 4

F x :

Pushing force on the right lower die in the x-axial direction [N], Fig. 3

F f :

Friction force the tube and dies in the guiding zone [N], Fig. 3

F z :

Force in the z-axial direction measured by load cell 2 or 3 [N], Fig. 3

P i, P j :

Hydraulic pressure in the tube at the next and previous moments [MPa], Eq 1

△p :

Hydraulic pressure difference inside the tube [MPa], Eq 1

P 0-3 :

Initial hydraulic pressure in the inner tube and hydraulic pressure generated by a different pressure generating system [MPa], Fig. 2

Fig. 2
figure 2

Schematic diagram of the self-developed measurement platform to determine the coefficient of friction (COF) in the guiding zone. The measurement platform has three hydraulic oil flow paths (I, II, and III) through three pressure generating systems and finally realizes the COF measurement between the TP2 copper tubular guiding zone and the die under three loading velocities

Full size image
N :

Normal contact force between the tube and dies in the guiding zone [N], Fig. 4

F :

Pushing force generated by the hydraulic pressure difference [N], Eq 1

f :

Internal friction force produced between the liquid layers [N], Eq 2

V :

Loading velocity of the pressure generating system [mm/s], Fig. 2

μ 0 :

Fluid viscosity of No. 46 hydraulic oil [Pa s], Eq 2

u d :

Fluid velocity distribution inside the tube [mm/s], Eq 4

u max :

Fluid velocity inside the tube [mm/s], Eq 5

μ :

Coefficient of friction (COF) in the guiding zone of the tube, Fig. 4

h :

Bulging height of the tube after tube hydroforming (THF) experiments, Table 6

t r :

Size of rupture position of the tube after THF experiments, Table 6

h a :

Mean of bulging height of the tube after THF experiments, Table 6

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Acknowledgments

The authors gratefully acknowledge the support of the National Natural Science Foundation of China (No. 51564007), the Natural Science Foundation of Guangxi Province (Nos. 2017GXNSFAA198133 and 2015GXNSFBA139223), and Guangxi Key Laboratory of Manufacturing System & Advanced Manufacturing Technology (No. 14-045-15-005Z).

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  1. Faculty of Mechanical & Electrical Engineering, Guilin University of Electronic Technology, Guilin, 541004, Guangxi, People’s Republic of China

    Jianping Ma, Lianfa Yang & Yulin He

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  1. Jianping Ma
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Correspondence to Lianfa Yang.

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Ma, J., Yang, L. & He, Y. Dynamic Frictional Characteristics of TP2 Copper Tubes during Hydroforming under Different Loading and Fluid Velocities. J. of Materi Eng and Perform 28, 3661–3672 (2019). https://doi.org/10.1007/s11665-019-04097-w

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