Numerical and Experimental Investigations on Tube Section Flattening for Parameter Identification and Advanced Material Modeling of Tubes
Abstract
:1. Introduction
2. Materials and Methods
2.1. Solution Approach: Transfer of Plane Material Testing Methods to Curved Tubes by Flattening Combined with Numerical Parameter Identification
- Separation of the tubes into ring sections and subsequent flattening, including measurement of relevant experimental quantities (force-time curve, geometric quantities).
- Directional separation of specimens from the flattened sheet and conventional testing in a tensile testing machine, including measurement of force and strain quantities.
- Construction of an inverse simulation model consisting of the combination of flattening and material testing, definition of the objective function as the difference between real and simulation results and inverse parameter identification by iterative simulation calculations.
2.2. Strategies for Process Implementation of Specimen Flattening
2.3. Material Modeling for Forming Simulation
2.4. Simulation Model
3. Results and Discussion
3.1. Simulation of Tube Section Flattening
3.2. Experimental Validation of the Flattening Simulation
4. Conclusions
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
References
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A | B | |||||||
---|---|---|---|---|---|---|---|---|
Group A: dominant test methods in the hydroforming context Group B: other established tube testing methods | longitudinal tube tensile test | ring hoop tension test | tube bursting test | tube flaring test | tensile test (entire tube cross section) | torsion test | lateral ring compression tests | ring expansion test |
Orientation-dependent testing | ± | − | − | − | − | − | − | − |
Preferred test direction: transversal | − | + | + | + | − | − | − | + |
Strain-rate-dependent testing | + | ± | ± | ± | + | + | ± | − |
Hydroforming-specific strain state | − | ± | + | − | − | − | − | − |
Isolated testing of weld seam | + | + | − | − | − | − | − | − |
Requirements: frictionless testing | + | ± | + | − | + | + | − | + |
Flattening by: | Pressing | Incremental Rolling | Swing Bending | |||
---|---|---|---|---|---|---|
Criteria from the context of experimental realization | ||||||
kinematics | ++ | simple | − − | complex, gradual forming with several incremental rolling steps necessary | − | complex |
forming machine and tool devices | + | easy, can be implemented in conventional tensile testing machines with tool | − | special rolling device necessary, very small roll diameters required | − | special forming and clamping device necessary |
material utilization | ++ | high, only small edge areas are not usable later | +/− | medium, there are always edge areas that cannot be rolled over | +/− | medium, big clamping areas are necessary |
flatness of specimen | + | good, springback compensation with overbending possible | +/− | gradually adjustable by roller movement | + | springback compensation with overbending or -stretching possible |
Criteria from the context of inverse evaluation | ||||||
amount of plastic deformation | +/− | small, only slight inhomogeneities | ++ | small, no inhomogeneities | +/− | small, only slight inhomogeneities |
numerical modelling and calculation effort | ++ | only small computation times, geometrically well defined | − − | high computation times due to incremental steps | +/− | medium computation times due to kinematics |
experimental data evaluation for inverse approach | + | forming force can be measured well, strains or thinning only offline | − | forming force only measurable with special device, strains or thinning only offline | − | forming force only measurable with special device, strains or thinning only offline |
influence of friction | − | local contact, static and dynamic friction | + | only due to rolling | ++ | no influence |
Chemical Composition (wt.-%) | C | Mn | Si | P | S | Fe |
---|---|---|---|---|---|---|
According to EN 10027-2 | max. 0.17 | max. 1.2 | max. 0.35 | max. 0.045 | max. 0.045 | balanced |
Used material | 0.08 | 0.60 | 0.014 | 0.007 | 0.010 | balanced |
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Reuther, F.; Winter, S.; Fritsch, S.; Kräusel, V.; Wagner, M.F.-X.; Psyk, V. Numerical and Experimental Investigations on Tube Section Flattening for Parameter Identification and Advanced Material Modeling of Tubes. J. Manuf. Mater. Process. 2023, 7, 91. https://doi.org/10.3390/jmmp7030091
Reuther F, Winter S, Fritsch S, Kräusel V, Wagner MF-X, Psyk V. Numerical and Experimental Investigations on Tube Section Flattening for Parameter Identification and Advanced Material Modeling of Tubes. Journal of Manufacturing and Materials Processing. 2023; 7(3):91. https://doi.org/10.3390/jmmp7030091
Chicago/Turabian StyleReuther, Franz, Sven Winter, Sebastian Fritsch, Verena Kräusel, Martin F.-X. Wagner, and Verena Psyk. 2023. "Numerical and Experimental Investigations on Tube Section Flattening for Parameter Identification and Advanced Material Modeling of Tubes" Journal of Manufacturing and Materials Processing 7, no. 3: 91. https://doi.org/10.3390/jmmp7030091