Numerical Simulation And Loading Trajectory Optimization Of Axial Feeding Bulging For T-tube

The tube axial-feeding bulging process is a new manufacturing technology formaking hollow and light parts with the advantage of light in weight, material andenergy saving and has a widely application. T-tube is non-symmetric parts, the formingprocess of T-tube is very complicated and the influence for the forming quality isvaried. In the process of axial feeding bulging, the rational matching of internalpressure and axial feeding is the key to forming process. In order to ensure the qualityof forming and avoid the defects (wrinkle and burst), optimizing the loading trajectoryis necessary.In the paper, based on the finite element simulation of ABAQUS, the parameterswere selected and analyzed including the set-up of material model, mesh subdivisionand boundary condition. In addition, the finite element model of T-tube axial feedingbulging was set and then the thickness distribution and the strain and stress of formingpart were analyzed. It were studied that the parameters of internal pressure and axialfeeding and the initial station of the branch bunch impacted on the height of branchand the distribution of wall thickness. The results indicated that when the axial feedingwas given, with the growth of internal pressure, the height of branch became higherbut the wall thickness on the top of branch became obviously thinner. And with theincreased of axial feeding, the height of branch tube became higher and the wallthickness was thicker and better. The distance between the punch of branch and thetube became farther, the wall thickness for forming part was more uneven, the wallthickness on the top of branch became thinner and then even the rupture was happened.The best value of parameters selected from the finite simulated results was notbest and most scientific, for they were not attained by the means of automatic search ofcomputer. In the paper, on the basis of the theory and algorithm of optimization, thedata transmission interface between the finite element simulation and the algorithm ofoptimization was set up by the means of editing the files of processing batch and text and macro command. And then the close connection between the finite elementsoftware and the optimization software was finished, so the automatic search functionin the computer was realized. The optimization of mathematic module of T-tube axialfeeding bulging was designed in the iSIGHT software and the response surface modulewas also set by the results of orthogonal experiment. The trajectory of axial feedingbulging was simulated. The results indicated that the loading trajectory of innerpressure was that the loading of internal pressure was firstly increased rapidly and thenloaded slowly or constant. On the contrary, the axial feeding was firstly feed slowlyand then increased quickly. The optimized branch height and thickness distribution forT-tube were made better than that before.