Hydroforming simulation in Abaqus

Workshop 1: Hydroforming simulation using SPH method

Hydroforming is a specialized metal forming process that enables the shaping of various metals like steel, stainless steel, copper, aluminum, and brass. It offers a cost-effective alternative to die molding by utilizing highly pressurized fluid to shape the metal. Two main classifications of hydroforming are sheet hydroforming and tube hydroforming. In sheet hydroforming, a single die and a sheet of metal are used. The sheet is driven into the die by high-pressure water, resulting in the desired shape. Tube hydroforming, on the other hand, involves expanding metal tubes using two die halves that contain the raw tube.

Hydroforming replaces the older method of stamping two separate parts and welding them together. It allows for more efficient manufacturing by eliminating welding and enables the creation of complex shapes and contours. Hydroformed parts offer numerous manufacturing advantages, including seamless bonding, increased strength, and the ability to maintain high-quality surfaces for finishing. Compared to traditional stamped and welded parts, hydroformed parts are lightweight, have a lower cost per unit, and exhibit a higher stiffness-to-weight ratio. Additionally, hydroforming can streamline the production of components in a single stage, resulting in labor, tool, and material savings. In this tutorial, the focus is on investigating sheet hydroforming.

The sheet in this simulation is made of aluminum material, and the behavior of water is modeled using the Us-Up equation of state. The simulation employs a dynamic explicit step with surface-to-surface contact. To model the behavior of water, the Smooth Particle Hydrodynamic (SPH) method is utilized. In the simulation, the punch is moved into the water, causing the water to exert significant pressure on the sheet. After a certain time, the sheet undergoes noticeable deformation, indicating the forming process taking place.

Workshop 2: Electro-Hydraulic Forming simulation of Sheet using time-pressure curve

The investigation in this simulation focuses on the Finite Element simulation of Electro-Hydraulic Forming of a sheet using a time pressure curve in Abaqus. Sheet metal forming processes involve applying force to modify the geometry of a piece of sheet metal without removing any material. This force causes the metal to undergo plastic deformation beyond its yield strength, allowing for bending or stretching into complex shapes without failure. Conventional sheet metal forming processes include bending, roll forming, deep drawing, and stretch forming.

However, advancements in technology have introduced high strain rate forming processes such as explosive metal forming, electro-magnetic pulse forming, and electro-hydraulic forming. These processes utilize high-pressure pulse generation from different energy sources. In this simulation, the blank is represented as a three-dimensional shell part with elastic-plastic material properties.

In this simulation, the validation of the paper has been conducted, and the simulation aligns well with the paper’s findings. The simulation utilizes a dynamic explicit step with surface-to-surface contact. A Time-Pressure curve is employed to model the pressure pulse. Throughout the simulation, the maximum displacement of the dome matches the results presented in the paper.