Studies On Hydroforming FEM Simulation And Experiment Of Complicated-Shape Bottle

Hydroforming has been widely used in automotive manufacturing industry and aviation field, with the advantages of light weight and material saving. It's the main technique of producing complicated hollow-shaped accessory. The forming process of work pieces is connected to many factors, of which the relationship between internal pressure and axis feeding is the most important.The strain and stress state in the shape-changing district during forming process is analyzed according to plasticity theory and the changing in wall-thickness for various stress state was given. Based on it, the forming process was simulated by finite element programming. The property of material flowing under various conditions, the distribution of strain and stress and the changing thickness of tube are researched. The affecting rule of internal pressure and axial-feeding quantity for forming is conformed.The aluminum tube used in our experiment is of diameter 66 mm and wall thickness 1.1 mm at the beginning. The complicated-shaped bottle with double belly-like was formed in two steps. The results of trails are similar to the results of simulation. The thickness distribution of the finished bottle is analyzed.The effect of different loading path during the course of hydroforming is researched in this dissertation. The common failure in forming process, such as cracking, wrinkle, is studied. The wrinkle phenomenon is mainly analyzed and the effect of internal pressure and feeding quantity to wrinkle is proved through experimental work.