Fracture and springback on Double Bulge Tube Hydro-Forming

This research aims to establish a basic understanding of Double Bulge Tube Hydro-Form processing of stainless steel deep drawn cups. The method is briefly reviewed by carrying out experimental tests and Finite element analysis. By measuring bulge height in both formed curves by Coordinate measuring machine (CMM) and thickness variation specimen by Ulterasonic thickness measurment device (UTM), it has been shown that maximum thinness occured where the bending is maximized. A finite element model is constructed to simulate the Double Bulge Tube Hydro Forming process and asses the influence of friction cofficient, tube Material properties and springback. It has been shown that material hardening coefficient had the most significant influence on formability characteristics during double bulge tube hydroforming. Also it is shown that springback has significant effect on tolerances of formed tube. Finally fracture strain was estimated by analytical method and compared with simulation results, also fracture location was predicted on Double Bulge Tube Hydro-Forming (DBTHF) by simulating the process.