Evaluation of load control end-feed in hydroforming of pre-bent DP600 steel tube using the extended stress-based forming limit curve (XSFLC) failure criterion

Bardelcik, Alexander and Worswick, Michael J. (2006) Evaluation of load control end-feed in hydroforming of pre-bent DP600 steel tube using the extended stress-based forming limit curve (XSFLC) failure criterion. JOURNAL OF COMPUTATIONAL AND APPLIED MECHANICS, 7 (2). pp. 133-154. ISSN 1586-2070

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Abstract

The work presented in this paper utilizes advanced finite element models of the pre-bending and hydroforming processes to investigate the effect of load control end-feed (EF) on the formability of DP600 steel tube in hydroforming. A model of a rotary-draw tube bender was used to simulate pre-bending. Validation of the pre-bending model showed good agreement with the pre-bending experiments. The hydroforming process was also successfully modelled and validated for a zero EF case. Increasing levels of EF were simulated and the corner-fill expansion of the tube was measured to assess the formability of the tube. The new and fully three dimensional Extended Stress-Based Forming Limit Curve (XSFLC) failure criterion was used to predict the onset of necking in the hydroforming simulations. In addition to varying the level of end-feed, two different pressurization schemes were investigated. The models showed that an increase in end-feed improved formability during hydroforming and also sensitivity to pressurization scheme was shown.

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