Simulation Analysis Of The Ordinal Hydro-Forming Process For Multi Ways Tube On Air Conditioning Header

Multi ways tube on air conditioning header is the main parts of condenser. The traditional Multi ways tube on air conditioning header was usually manufactured by welding forming. But this technique exist some defects such as loose and holes, and they would affect the service life of the condenser.This paper studies the forming process of multi ways tube, and put forward the Ordinal Hydro-Forming. The Hydro-Forming is an advanced manufacturing technology of hollow components. It not only lightweight and integration, but also saving energy, saving material, and conform to the trend of the environmental protect development. In this paper, the deformation rule is studied during the Hydro-Forming process in a certain orderly forming scheme. In the production and application, the multi ways tube on air conditioning header is manufactured integrated, and it change the traditional method. What’s more, the mechanical properties were improved. The main contents are as follows:Approximate theoretical analysis method is used to study the paper, and assume that deformation is ax symmetric or plane state. The principal stress method was used to analysis the mechanical properties and rules during the hydro-forming. The related basic theory was set up during the hydro-forming for multi ways tube.The numerical simulation analysis method is also used to study the rule of metal flow thickness distribution during the Ordinal Hydro-Forming. The results show that there is an obvious metal flow in the end filling zone and bulge direction. The Metal between bulges will also flow along the horizontal direction, but the flow is quite small. The thickness distribution is that there is increase in end filling zone. On the contrary, there is decrease in branch zone. The biggest wall thickness is in tube ends, the minimum thickness is in branch top. What’s more, this paper analysis the influence of loading paths and process parameters for hydro-Forming. The loading paths of hydro-Forming are put forward based on the metal flow rule. The results show that the slope of straight line loading path has a significant effect on branch height; the greater slope, the higher height, but the maximum and minimum wall thicknesses have little variation. What’s more, fold line loading path can effectively improve the branch height while the shock loading path can effectively improve the wall thickness’s uniformity. Process parameters such as branch diameter, branches distance, tube thickness, branch numbers and die fillet radius affect the branch height. The results show that with the increase of branch diameter, die fillet radius and tube thickness, the branch height increases. It also shows that with the increase of branch numbers and branches distance, the branch height decreases generally.The uniform design method, the artificial neural network and Matlab neural network toolbox are used to set up the forecasting model of branch height and wall thickness distribution. The model can effectively predict the branch height and wall thickness distribution.