The Design And Development Of High-strength Alloy Steel Tube Hydroforming Test Machine

Tube hydroforming technology effectively combines the character of structured light-weight with flexible processing technology. It's a near net shape technology which belongs to special plastic forming. Thus, many developed countries have done a lot of research on the technology and gradually apply it from automotive to aerospace, military, supplies and other applications. Our research on the forming equipment, processing parameter control and model design, etc are lagging behind other countries, especially it is quite scarce in verification of computer simulation of high-alloy tube forming process. So, promoting the design and manufacture of high-alloy tube hydroforming test machine actively, and ultimately establishing a calibration verification system of tube hydroforming process is a necessary and important work.Firstly, this paper analysed the features of tube hydroforming and the largest geometric parameters of the forming parts; Then derived mathematical formula based on the free-bulge forming model with both ends fixed and non-axial feed; After that, calculated the maximum forming parameters; Finally ascertain the hydroforming experimental machine's main technical parameters.The hydraulic experimental machine adopted four-cylinder clamping, four floating columns and auxiliary clamping structure, which increased the clamping pressure, compact structure, the effective space, and so on. It aslo adopted triple feed and balance-conversion structure, which expanded the scope of the forming. In addition, the machine realized the modular and lightweight structure, reduced its weight, and could achieve the work of multiple machines combined, and formed a large workpiece. In the hydraulic system, a unique high and low voltage conversion circuit and automatic lubrication system of model were designed, cartridge valve and the digital synchronization valve were extensively adopted. All of that was to improve the system's efficiency, ameliorate the lubrication conditions, improve the speed and accuracy of system's response. In short, the machine can actualize the validation of free bulging, bulging axial, T-tube forming, cross-tube bulge and other processing methods. It set up the foundation for constitution of experimental platform of hydraulic forming and numerical simulation of hydraulic forming.the structure of this machine was optimized, and the feasibility of the hydraulic system was verified by using numerical modeling and simulation, and these work will provide a reliable reference for actual production and manufacturing in future.