Hydroforming Limits in Metal Bellows Forming Process

Metal bellows have wide applications in aerospace, micro-electromechanical, and industrial systems. Some defects such as wrinkling and bursting may occur during the metal bellows forming process. In contrast to wrinkling, bursting is generally classified as an irrecoverable failure mode. In order to...

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Bibliographic Details
Published in:Materials and manufacturing processes 2010-12, Vol.25 (12), p.1413-1417
Main Authors: Faraji, Gh, Hashemi, R., Mashhadi, M. Mosavi, Dizaji, A. F., Norouzifard, V.
Format: Article
Language:English
Subjects:
Bellows
Bursting
Computation
Computer simulation
Experiment
Finite element method
Forming
Mathematical analysis
Mathematical models
Necking
Simulation
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Summary:Metal bellows have wide applications in aerospace, micro-electromechanical, and industrial systems. Some defects such as wrinkling and bursting may occur during the metal bellows forming process. In contrast to wrinkling, bursting is generally classified as an irrecoverable failure mode. In order to obtain sound products, it is necessary to predict the bursting behavior. Bursting in the tube-bulging process is a consequence of necking. Thus, prediction of necking initiation is a vital issue before designing the details of the process. In this article, the forming limit diagram (FLD) and the forming limit stress diagram (FLSD) have been used to predict the initiation of necking in metal bellows forming processes. Afterwards, the implementation of the forming strain and stress limit diagrams into finite element (FE) numerical simulations for the forming of the metal bellows is established by using an explicit FE code (LS-Dyna). Finally, the results of finite element method (FEM) and experiments show good agreement.
ISSN:1042-6914
1532-2475
DOI:10.1080/10426914.2010.499579