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TUBEHYDRO 2019
The 9th International Conference on Tube Hydroforming November, 18-21, 2019. Kaohsiung, Taiwan
Organizer:
National Sun Yat-sen University(NSYSU)
Co-organizer:
Taiwan Society for Technology of Plasticity Japan Society for Technology of Plasticity China Society for Technology of Plasticity Korean Society for Technology of Plasticity
Sponsors:
Ministry of Science and Technology Ministry of Education
Kaohsiung City Government
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Contents
Welcome Message ... 3
Committee ... 4
Program at A Glance ... 6
Information on Technical Program ... 7
Program ... 8
Social Program ... 13
Cultural Excursion ... 14
Technical Tours ... 14
Kaohsiung Harbor Cruise ... 15
Transportation and Venue ... 16
Accommodations ... 27
General Information ... 28
Abstract ... 29
Sponsor ... 111
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Welcome Message
It is my great pleasure and honor to invite all of you to the 9th International Conference on Tube Hydroforming (TUBEHYDRO 2019) in Kaohsiung, Taiwan. Since the first tube hydroforming conference was held in Kariya, Japan (2003), these TUBEHYDRO conferences have been held at Kyungju, Korea (2005), Harbin, China (2007), Kaohsiung, Taiwan (2009), Hokkaido, Japan (2011), Cheju, Korea (2013), Xian, China (2015), Bangkok, Thailand (2017). This conference will focus not only on the recent experimental, computational and theoretical research achievements on tube hydroforming technologies, but also on the industrial applications and developments. Especially some research results on new forming processes, such as hydropiercing, hydro-flanging, hydro-inlaying, and movable die compound forming, are also covered in the conference.
Four plenary lectures conveying the latest development and innovation on tube hydroforming technologies in Japan, China, Taiwan, and USA, and additionally 37 technical papers in 6 different sub-topics will be presented in the conference.
In 2009, the forth International conference on Tube hydroforming was held in Kaohsiung, Taiwan.
Kaohsiung city has changed a lot in recent years. Kaohsiung is a heavy industrial city in Taiwan. Many big manufacturing companies, such as China Steel Corporation (CSC), China Ship Building Corporation (CSBC), and C.S. Aluminium Corporation (CSALU), and Metal Industrial Research and Development Center (MIRDC) are all located in Kaohsiung. Kaohsiung Light Rail Transportation (KLRT) was just completed in 2015, which connects some shopping and commercial centers, such as Dream Mall, Commerce and Trade Park, Software Technology Park, Pier-2 Art Center, Hamasen (Sizihwan), etc. A culture excursion of Chimei Museum and a technical tour to CSC as well as a Kaohsiung harbor cruise are organized in the last day of the conference. I hope you can take the opportunity to experience the ocean capital culture of Kaohsiung.
Finally, on behalf of the organizing committee, I would like to express my sincere gratitude to all the authors for their contributions as well as all the committee members for their efforts to make this conference as perfect as possible.
Yeong-Maw Hwang Conference chairman
9th International Conference on Tube Technology (TUBEHYDRO2019)
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Committee
Conference Honorary Chair
Yinig-Yao Cheng, President of National Sun Yat-sen University (NSYSU), Taiwan Ken-ichi Manabe, Tokyo Metropolitan University (TMU), Japan
Conference Chair
Yeong-Maw Hwang, National Sun Yat-sen University (NSYSU), Taiwan Conference Co-Chair
Fuh-Kuo Chen, National Taiwan University, Taiwan
Huiwen Hu, National Pingtung University of Sciences and Technology, Taiwan Steering Committee
Yeong-Maw Hwang, National Sun Yat-Sen University, Taiwan Heon-Young Kim, Kangwon National University, Korea
Takashi Kuboki, The University of Electro-Communications, Japan Ken-ichi Manabe, Tokyo Metropolitan University, Japan
Purit Thanakijkasem, King Mongkut’s University of Technology Thonburi, Thailand Shijian Yuan, Harbin Institute of Technology, China
International Scientific Committee
Fuh-Kuo Chen, National Taiwan University, Taiwan Jun Chen, Shanghai, Jiaotong University, China Yoodong Chung, Hyundai Steel, Korea
Tsuyoshi Furushima, The University of Tokyo, Japan Sadakatsu Fuchizawa, Utsunomiya University, Japan
Huiwen Hu, National Pingtung University of Sciences and Technology, Taiwan Haomin Jiang, Bao Steel Group Corp., China
Kazuaki Katou, Sango Co., Japan Jeong Jin Kang, KITECH, Korea
Yong Nam Kwon, Korea Institute of Materials Science, Korea Yukihisa Kuriyama, The University of Tokyo, Japan
Yeonsik Kang, POSCO, Korea Hyung Seop Kim, POSTECH, Korea
Young Suk Kim, Kyungpook National University, Korea Yannis Korkolis, The Ohio State University, USA
Takashi Kuboki, The University of Electro-Communications, Japan Lihui Lang, Beihang University, China
Myoung-Gyu Lee, Seoul National University, Korea
Young-Seon Lee, Korea Institute of Materials Science, Korea Taeg Jae Lee, Hwashin Co. Ltd., Korea
Gang Liu, Harbin Institute of Technology, China
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Rendong Liu, Anshan Iron & Steel Group Corp., China
Xin Lu, Institute of Advanced Manufacturing Technology, China Ninshu Ma, Osaka University, Japan
Sasawat Mahabunphachai, National Metal and Materials Technology Center, Thailand Masaaki Mizumura, Nippon Steel & Sumitomo Metal Corp., Japan
Younghoon Moon, Pusan National University, Korea Xiongqi Peng, Shanghai Jiaotong University, China Atsushi Shirayori, Utsunomiya University, Japan
Purit Thanakijkasem, King Mongkut’s University of Technology Thonburi, Thailand Noah Utsumi, Saitama University, Japan
Wencai Xie, FAW Group Corp., China Yoshinori Yoshida, Gifu University, Japan
Shoichiro Yoshihara, Shibaura University of Technology, Japan Mei Zhan, Northwestern Polytechnic University, China
Shengdun Zhao, Xi’an Jiaotong University, China Local Executive Committee
Prof. Fuh-Kuo Chen (National Taiwan University) Mr. Chih-Yu Chuang (Metal Industries R&D Centre)
Prof. Huiwen Hu, (National Pingtung University of Sciences and Technology) Prof. Cho-Pei Jiang (National Formosa University)
Prof. Yeong-Maw Hwang (NSYSU) Prof. Keng-Hao Liu (NSYSU)
Prof. Chin-Tarn Kwan (Nan Kai Institute of Technology) Prof. Chang-Cheng Chen (Taipei City Univ. Sci. Tech.) Prof. Shen-Yung Lin (National Formosa University) Dr. Yi-Kai Lin (China Steel Corporation)
Prof. Cheng-Tang Pan (NSYSU) Prof. Jau-Woei Perng (NSYSU)
Prof. Gow-Yi Tzou (Chung Chou Univ. Sci. Tech.)
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Program at a glance
Date Time
November 18 (Monday)
November 19 (Tuesday)
November 20 (Wednesday)
November 21 (Thursday)
Morning Opening ceremony
(8:50-9:00)
WA1
(8:50-10:20) Chairmen:
F. Schieck S. Yoshihara
WB1
(8:50-10:20) Chairmen:
S.Alexandrov G.Y. Tzou
Culture excursion (Chimei Museum) Plenary session I
(9:00-10:20) Chairman:
K. Manabe Coffee break (10:20-10:50)
Coffee break (10:20-10:50) Plenary session II
(10:50-12:10) Chairman:
H. Hu
WA2
(10:40-12:10) Chairmen:
A. Shirayori S. Yuan
WB2
(10:40-12:10) Chairmen:
Y. Korkolis C.C. Chen Lunch
(12:10-13:30)
Lunch
(12:10-13:30)
Afternoon T1
(13:30-15:20) Chairmen:
F.K. Chen, D.Y. Kim
WA3
(13:30-15:20) Chairmen:
A.Tomizawa G. Liu
WB3
(13:30-15:40) Chairmen:
S. Supriadi D.C. Chen
Technical tours (China Steel Corporation) City tour (Kaohsiung harbor cruise) Registration
(17:00-20:00)
Coffee break (15:20-15:40) T2
(15:40-17:30) Chairmen:
T. Kuboki, P. Thanakijkasem Evening
(18:00-20:00)
Welcome Reception (18:00-20:00)
Dinner (18:00-20:00)
Banquet (18:00-20:30)
Farewell party (18:00-20:30)
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Information on Technical Program
Information for Session Chairs
The session chairs are expected to arrive at the session room at least 10 minutes prior to the session.
The session chairs will be given the brief presenter’s profile on the desk. Please communicate with the speakers before the session starts and make sure that they are all present in the session. In the case of missing speaker, please write down his name and later report to conference information desk. Each keynote speaker will have 30 minutes for presentation and discussion, and each ordinary speaker will have 20 minutes for presentation and discussion. It is recommended to save the last 5 minutes for discussion. Please ring the bell once one minute before the presentation finishes and twice as the presentation time uses up. The session chairs are recommended to advise those who bring their own laptops to have compatibility test before the session begins.
Information for Oral Presentations
Presenters at all sessions are required to report to the session chairs before the session starts. Each keynote speaker will have 25 minutes for presentation and 5 minutes for discussion, and each ordinary speaker will have 15 minutes for presentation and 5 minutes for discussion. Each session room will be equipped with a laptop computer and a projector. Presenters are expected to upload their presentation files from their USB memory sticks 10 minutes before the session begins.
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Program
Monday, November 18, 2019
17:00 -20:00 Registration, At IR6002 18:00 -20:00, Welcome reception, At IR6002
Tuesday, November 19, 2019 8:10 -17:00 Registration, At IR1003, IR6002 (afternoon)
8:50 -9:00 Opening ceremony, At IR1003
Plenary session (I)
At IR1003, Chairman: Prof. Ken-ichi Manabe
9:00 -9:40 (P1) Recent Trend and Perspectives in Tube Forming Prof. Takashi Kuboki (Japan)
9:40-10:20 (P2) New Processes and Applications of Rapid Hot Gas Forming of Light-alloy Tubes Prof. Shijian Yuan (China)
10:20-10:50 Coffee break, At IR1003 (Group photographing)
Plenary session (II)
At IR1003, Chairman: Prof. Huiwen Hu
10:50 - 11:30 (P3) A Study on Tube-Hydroformed Automotive Twist Beam Design Prof. Fuh-Kuo Chen (Taiwan)
11:30-12:10
12:10-13:30 Lunch, At IR6002
13:30-15:40 November 19, 2019
T1: Experimental/Theoretical results of tube hydroforming (I) At room IR6002A, Chairmen: Fuh-Kuo Chen and Daeyong Kim
13:30-14:00 (T1-1)# Shape Distortion Effect in Tube Hydroforming of SS304 Bellow Neranuch Usamith and Purit Thanakijkasem* (Thailand)
14:00-14:20 (T1-2) Experimental Investigation of Tube Drawing Process with Diameter Expansion
Shohei Kajikawa*, Hikaru Kawaguchi, Takashi Kuboki, Isamu Akasaka, Yuzo (P4) Ductile Fracture of Aluminum Tubes for Hydroforming Applications Prof. Yannis Korkolis (USA)
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Terashita and Masayoshi Akiyama (Japan)
14:20-14:40 (T1-3) Improvement of Dimensional Precision in Two-step Shear Bending Method Using Mandrels
Takashi Kuboki*, Daisuke Kusuda, Shohei Kajikawa, Takahiro Noguchi and Kazuaki Adachi (Japan)
14:40-15:00 (T1-4) An Efficient Method for Analysis of Expanding Hollow Clad Cylinders of Strain Hardening Material
Sergei Alexandrov*, Lihui Lang and Yeau-Ren Jeng (Russia)
15:00-15:20 (T1-5) Suppression of Undesirable Phenomenon of Thin-walled Rectangular Tube in Rotary Draw Bending
Yoshihisa Saito*, Noah Utsumi and Masashi Yoshida (Japan) 15:20-15:40 Coffee break, At IR6002
15:40-17:30 November 19, 2019
T2: Experimental/Theoretical results of tube hydroforming (II) & Miscellaneous forming At room IR6002A, Chairmen: Takashi Kuboki and Purit Thanakijkasem
15:40-16:10 (T2-1)# Failure Limit Evaluation of 7xxx Aluminum Alloy Sheet at Elevated Temperatures
Donghoon Yoo, Yong-Nam Kwon and Daeyong Kim* (Korea)
16:10-16:30 (T2-2) Application of Heat Assisted Dieless Bellows Forming Technology to Various Materials and Dimensions of Tubes
Tsuyoshi Furushima*, Zicheng Zhang and Osamu Sasaki (Japan)
16:30-16:50 (T2-3) Deformation to Taper Shape by Warm Tube Hydroforming of Small Diameter A1100 Aluminium Tube
Taisuke Miyagawa*, Hajime Yasui, Shoichiro Yoshihara, Ryuichi Yamada and Yasumi Ito (Japan)
16:50-17:10 (T2-4) Crash Characteristics of Partial-quenched Products by 3 Dimensional Hot Bending and Direct Quench
Atsushi Tomizawa*, Sanny Soedjatmiko Hartanto, Kazuo Uematsu and Naoaki Shimada (Japan)
17:10-17:30 (T2-5) New Concept of Hydroforming Process for Microtubes with Large Ratio of Length to Diameter
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Zicheng Zhang*, Tsuyoshi Furushima, Ken-ichi Manabe, Honghao Liu and Bin Li (China)
18:00-20:00 Dinner, At Sunset beach resort
Wednesday, November 20, 2019 8:50-10:20, November 20, 2019
WA1: Experimental/Theoretical results of tube hydroforming (III) At room IR6002A, Chairmen:
Frank Schieck and Shoichiro Yoshihara
WB1: Numerical simulation of tube hydroforming & Hydropiercing and hydrojoining
At room IR6002B, Chairmen: Sergei Alexandrov and Gow-Yi Tzou 8:50-9:10 (WA1-1) Development of Tube
Flaring Technology for Large Expansion
Shohei Tamura*, Keinosuke Iguchi and Masaaki Mizumura (Japan)
8:50-9:20 (WB1-1)# Hydroforming Simulation of Thin Metal Tube
Chang-Cheng Chen*, Jun-Ying
Huang, Cho-Pei Jiang and Dyi-Cheng Chen (Taiwan)
9:10-9:30 (WA1-2) Study on the Joining of Brass Rings and Steel Shafts by Metal Flow Joining Method Masaya Ohira* and Atsushi Shirayori (Japan)
9:20-9:40 (WB1-2) Advanced CAE Method for Springback Compensation and Process Robustness Analysis of Bent and Hydroformed Parts
Giampaolo Moncelsi* and Werner Teufel (Italy)
9:30-9:50 (WA1-3) Influence of Internal Pressure and Axial Compressive Displacement on Formability of Small Diameter ZM21 Magnesium Alloy Tube on Warm Tube
Hajime Yasui*, Taisuke Miyagawa, Shoichiro Yoshihara, Tsuyoshi Furushima, Ryuichi yamada and Yasumi Ito (Japan)
9:40-10:00 (WB1-3) Loading Path Design of Tube Hydroforming Using Movable Dies
Yeong-Maw Hwang and Yau-Jiun Tsai* (Taiwan)
9:50-10:20 (WA1-4) # Study on Formability and Fracture of Ti-alloy Tube by Hot Gas Bulging Tests
Yong Wu*, Shiqiang Zhu and Gang Liu (China)
10:00-10:20 (WB1-4) Study of
Hydro-piercing-flanging and Nut Laying
Yeong-Maw Hwang and Hong-Nhan Pham* (Taiwan)
10:20-10:40 Coffee break, At IR6002
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10:40-12:10, November 20, 2019
WA2: Formability of tube hydroforming At room IR6002A, Chairmen: Atsushi Shirayori and Shijian Yuan
WB2: Sheet hydroforming and
hydro-bulging & Miscellaneous forming At room IR6002B, Chairmen: Yannis Korkolis and Chang-Cheng Chen 10:40-11:10 (WA2-1)# One-sided Rubber Bulging
Test to Measure Forming Limit Strains of Metal Tube
Kana Nakanahara* and Hidenori Yoshimura (Japan)
(WB2-1)# A Vision-based Fuzzy Control for Semi-dieless Bellows-forming by Local Heating Technique
Sugeng Supriadi*, Tsuyoshi Furushima and Ken-ichi Manabe (Indonesia)
11:10-11:30 (WA2-2) Study of Circular and Square Aluminum Alloy Deep Drawing Dyi-Cheng Chen*, Jia-Yue Guo, Cheng-Yu Li, Yu-Yu Lai and Yeong- Maw Hwang (Taiwan)
(WB2-2) Effect of Deformation Path in Forming 3D Closed-Section Parts from Sheet Metal
Masahiko Sato*, Masaaki Mizumura, Tohru Yoshida,Yukihisa Kuriyama, Katsuyuki Suzuki and Atsushi Tomizawa (Japan)
11:30-11:50 (WA2-3) Modeling Dynamic
Recrystallization of Stainless Steel in the Coupled Crystal Plasticity and Cellular Automata Approach Jinheung Park*, Matruprasad Rout, Kyung Mun Min, Shuaifeng Chen and Myoung-Gyu Lee (Korea)
(WB2-3) Uncertainty in Forming PET-Laminated Tin-Free Steel Sheet to Waving Defect in Lithographic Food Can Natthawat Chuchot* and Purit
Thanakijkasem (Thailand)
11:50-12:10 (WA2-4) Formability Analysis of Fiber Metal Laminates by an Innovative Method in Hydroforming
Lei Li, Lihui Lang* and Blala Hamza (China)
(WB2-4) Study of Friction Tests of Strips with Variant Relative Speeds
Yeong-Maw Hwang, Hao-Ping Yu,
Chiao-Chou Chen* and Chih-Pin Chiang (Taiwan)
12:10-13:30 Lunch, At IR6002
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13:30-15:40, November 20, 2019
WA3: New Processing Technology and Innovation, Numerical simulation of tube hydroforming & ERW and laser welding tubes for hydroforming
At room IR6002A, Chairmen: Atsushi Tomizawa and Gang Liu
WB3: Miscellaneous forming
At room IR6002B, Chairmen: Sugeng Supriadi and Dyi-Cheng Chen
13:30-14:00 (WA3-1) # Tool Aspects for High Temperature Level Gas Forming Matthias Demmler, Andre Albert and Frank Schieck* (Germany)
(WB3-1)# Plastic Mechanics of Pipe Drawing with Rotating Die Considering Shear Friction
Gow-Yi Tzou*, Un-Chin Chai, Hsiang-Yu Teng and Shih-Hsien Lin (Taiwan)
14:00-14:20 (WA3-2) Flexible Diameter Reduction of Tubes with Planetary Balls
Takayuki Ikeda*, Shohei Kajikawa and Takashi Kuboki (Japan)
(WB3-2) Press Bending of AZ31 Magnesium Alloy Extruded Tube Osamu Hasegawa* and Ken-ichi Manabe (Japan)
14:20-14:40 (WA3-3) Recent Developments in Tube Hydroforming of the MIRDC
Yi-Chun Chen*, Chih-Yu Chuang,
Cheng-Kai ChiuHuang and Ping-Kun Lee (Taiwan)
(WB3-3) Effect of Thickness on Mechanical Joining Between the Aluminum Tube and Sheet by Electromagnetic Expansion
Hyeonil Park*, Jinwoo Lee and Daeyong Kim (Korea)
14:40-15:00 (WA3-4) A New Method for
Hydroforming of a Variable-diameter Part with Partially Overlapping Tubular Blanks
Cong Han* and Hao Feng (China)
(WB3-4) Development of FEM Analysis Model of Folding Process of Creased Paperboard Using Non-linear Spring Based Cohesive Zone Model Plus Shear Yield Glue Model
Shigeru Nagasawa, Weerayut Jina, Tetsuya Yamamoto, Takaomi Nagumo*
and Shigekazu Suzuki (Japan) 15:00-15:20 (WA3-5) Advances in Hydroforming
Processes and Applications
Shi-Hong Zhang*, Dayong Chen, Yong Xu and Yan Ma (China)
(WB3-5) Hot Gas Bulging of Titanium Alloy Tube Using Current Resistance Heating
Gang Liu*, Kexin Dang and Shijian Yuan (China)
18:00-20:30 Banquet, At Ambassador Hotel
# Keynote papers
* Presenter of the paper
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Social Program
1. Welcome Reception
Date: Monday, November 18, 2019 Time: 18:00~20:00
Place: NSYSU
International Research Building IR6002 and IR6008 2. Dinner
Date: Tuesday, November 19, 2019 Time: 18:00~20:00
Place: Sunset Beach Resort (In NSYSU)
Sizihwan Bay is located on the west side of Kaohsiung City, to its north, Shou Mountain and the Cijin peninsula to its south. It is a natural bay renowned for its beaches and natural shoals. Located within the grounds of National Sun Yat-sen University, it is Kaohsiung's most famous beach and the best place in town to watch the sun set.
3. Banquet
Date: Wednesday, November 20, 2019 Time: 18:00~20:30
Place: Ambassador Hotel Kaohsiung.
The Ambassador Hotel Kaohsiung is located at the Love River bank, overlooking the enchanting Shou Mountain, and close to the beautiful Mingsheng Road boulevard, where you can experience the beauty of Kaohsiung from any angle. Thus making it a gourmet and fashion heaven for all guests!
4. Farewell Party
Date: Thursday, November 21, 2019 Time: 18:00~20:30
Place: Her Bian Banquet Hall
Banana Pier was built at Kaohsiung Harbor’s Wharf No. 3 in 1963. The open-air design, unique among storage facilities at the port, enabled the natural ventilation required for storage of bananas.
In 2010, the building was renamed as “Banana Pier”. The building has a unique location opposite the first entrance of the harbor, with its back to the hills and its face to the sea. On the second floor of the historic building is the unique Her Bian Banquet Hall.
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Cultural Excursion
Date : November 21, 2019
Time : AM 8:30~ PM1:30 (Including the lunch)
Place : No. 66, Sec. 2, Wenhua Road, Rende District, Tainan CHIMEI Museum is a comprehensive museum with
wide collections of Western art, musical instruments, weaponry and natural history. There are permanent exhibition galleries, one temporary exhibition gallery and sculpture halls in the main building. As a museum for all, we hope our visitors will enjoy and cherish these timeless valuables and find their favorites among them.
Technical Tours
Date : November 21, 2019 Time : PM 2:00~ PM4:00
Place : Chung-Kang Road, Siaogang District, Kaohsiung CSC is an integrated steel producer that has produced
steel plates since the commencement of its plate mill. Through developments and improvement over the years, CSC’s comprehensive steel plate grades have fulfilled industrial requirements demanded by general structure and building applications such as earthquake resistance, bridge and welding, as well as other uses like construction of ships, pressure vessels, line pipes, HIC resistance, laser-cutting, etc.
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Kaohsiung Harbor Cruise
Date : November 21, 2019 Time : PM 4:00~ PM 5:30
Place : No.62.Linhai 2nd Road, Gushan District, Kaohsiung The Kaohsiung Harbor is the largest harbor in Taiwan,
handling approximately 10 million twenty-foot equivalent units (TEU) worth of cargo in 2017. The port is located in southern Taiwan, adjacent to Kaohsiung City. The port occupies nearly 27 sq. km, with a shipping channel of 18 km. in length. The harbor contains 106 berths, 5 container terminals, which allows ships under 100,000 DWT to navigate, and 145 ships to berth simultaneously.
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Transportation and Venue
Conference Site: NSYSU Building of International Research, IR6002 NSYSU MAP：
A. Entrance of Tunnel
B. Conference Site: NSYSU Building of International Research C. NSYSU Main Entrance
D. Sunset Beach Resort (11/19 dinner)
A
B C D
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Layout of NSYSU Building of International Research 1F Opening Ceremony and Plenary Sessions at IR1003 for 11/19 Morning
IR 1003 Registration Desk
Entrance
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Layout of NSYSU Building of International Research 6F Parallel Sessions at IR6002 on 11/19 Afternoon and 11/20 Whole Day
IR6002 A | B Elevator
IR6008 VIP Room
(welcome reception)
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Traffic Information A. From Taoyuan International Airport (IATA: TPE)
Airport(TPE)
THSR Taoyuan
THSR Zuoying
Airport MRT (30 min.)
THSR (1.5 hr.)
KRT Red Line(13 min.)
Formosa Boulevard station
Sizihwan station
NSYSU
Walk
KRT Orange Line(6 min.)
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B. From Taipei Song Shan Airport (IATA: TSA)
NSYSU
Walk(15 min.) Taipei train station
THSR Zuoying
Formosa Boulevard station
Sizihwan station
TRT (20 min.)
THSR (1.5 hr.)
KRT Red Line(13 min.)
KRT Orange Line(6 min.) Airport(TSA)
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C. From Kaohsiung International Airport (IATA: KHH)
Notes:
a. Abbreviation
THSR Taiwan High Speed Rail
KRT Kaohsiung Rapid Transit
TRT Taipei Rapid Transit
b. Alternative way from Kaohsiung International Airport to NSYSU is taking taxi that spends NT$350 and 40 minutes.
Formosa Boulevard station
Sizihwan station
KRT Red Line(16 min.)
KRT Orange Line(6 min.) Airport(KHH)
Walk(15 min.)
NSYSU
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c. Conference shuttle bus service 2019/11/18
Starting Through Terminal
16:40 Ambassador 16:45 Fullon 16:55 NSYSU
20:10 NSYSU 20:20 Fullon 20:25Ambassor
2019/11/19
Starting Through Terminal
08:00 Ambassador 08:05 Fullon 08:15 NSYSU
20:10 NSYSU 20:20 Fullon 20:25Ambassor
2019/11/20
Starting Through Terminal
08:00 Ambassador 08:05 Fullon 08:15 NSYSU
17:30 NSYSU 17:40 Fullon 17:45 Ambassador
20:45 Ambassador 20:50 Fullon 21:00 NSYSU
2019/11/21
Starting Through Terminal
08:30 NSYSU 08:40 Fullon 08:45 Ambassador
20:30 Banana Pier 20:35 Fullon, 20:40 Ambassador 20:55 NSYSU
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THSR MAP
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KRT MAP
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Map for KRT Sizihwan station to NSYSU International Research Building (Conference Site)
Notes:
1.Bus stop (in front of gymnasium) on the map:
2.Alternative way by bus (O1, Orange 1), every 10-15min.(NT$12).
Entrance of Tunnel
KRT Sizihwan International Research
Building
(Conference Site)
KRT Sizihwan station
NSYSU International Research Building (Near NSYSU Administration Building)
)
Bus (O1, Orange 1)
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Map and Routine for Shuttle Bus
A. NSYSU B. Fullon Hotel
C. Ambassador Hotel ( 11/20 Banquet)
D. Her Bian Banquet Hall (11/21 Farewell Party) Notes:
1. Shuttle Bus Routine: The Blue Indicator Line.
A
B
C
D
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Accommodations
Two Hotels are recommended.
1. The Fullon Hotel Kaohsiung
Fullon Hotel Kaohsiung is located on the intersection of Wufu 4th Road and Dacheng Road, Yancheng District. It has a great geographical location and convenient transport. In certain rooms, guests can gaze into the broad view of Kaohsiung Harbor. In some other rooms, guests can watch the beautiful lights along Love River. During your stay in the
hotel, you can see lots of skyscrapers in Kaohsiung, presenting a modern urban scene. You can also gaze into Kaohsiung Harbor to see a grand view of the large ship made port.
2. The Ambassador Hotel Kaohsiung
Enjoy the best of business combined with relaxed resort-style splendor at Ambassador Hotel Kaohsiung. Located in downtown Cianjin District, the hotel is a stylish urban retreat on the picturesque banks of the Love River, ideal for a romantic stroll. Pier-2 Art Center, Love Pier and Liuhe Night Market are all within five minutes’ drive
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General Information
About Kaohsiung
Kaohsiung is located at Taiwan’s Southwestern region and is a long narrow stretch of land. Its total area consists of 2952 square kilometers.
Chianan and Pingtung plains are located on the north and east sides.
The Taiwan Straits are located to the west and the Bashi Channel to the south.
Geographically it is in an ideal location. The large harbor makes it an important trade and commerce stop along the Northeast Asia / South Pacific passageway. This has quickly propelled the development of this international city.
Kaohsiung has an international airport with direct flights to a variety of Asian cities. Other international cities can be reached by transferring at Taiwan Taoyuan International Airport in Taoyuan. There are approximately 50 flights a day between Taipei and Kaohsiung. The flight takes approximately 50 minutes. The High Speed Rail takes 90 minutes
Climate & Weather
The average annual rainfall is 1810.3 mm. The rainy season lasts from May to October. The average temperature is 24.4℃. July is the hottest month(about 32℃) and January the coldest. There is little difference between daytime and nighttime temperatures.
Currency & Traveler's Check
The Republic of China's unit of currency is the New Taiwan Dollar (NT$), which has five denominations in paper money and five in coins. Paper money comes in NT$2000, NT$1000, NT$500, NT$200, and NT$100 denominations. Coins come in NT$50, NT$20, NT$10, NT$5 and NT$1 denominations.
US$1 is equivalent to approximately NT$31. Hotels, department stores, airports, larger restaurants and shops accept credit cards.
Many Taiwan's local stores do not receive Traveler's Check, therefore travelers who have Traveler's Check, please exchange to NT dollars.
Service fee
Service charges are usually included in your bill on the price of rooms, meals, and other services at hotel and restaurant. Sometimes, expensive restaurant and luxury hotels may additionally plus a service charge of 10% on your normal price of your par value.
Electricity
Taiwan uses electric current of 110 volts at 60 cycles, appliances from Europe, Australia or South-East Asia will need an adaptor or transformer. Many buildings have sockets with 220 volts especially for the use of air conditioners.
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Abstract
Recent Trends and Perspectives in Tube Forming ... 31 New Processes and Applications of Rapid Hot Gas Forming of Light-alloy Tubes ... 33 A Study on Tube-Hydroformed Automotive Twist Beam Design ... 35 Ductile Fracture of Aluminum Tubes for Hydroforming Applications ... 37 Shape Distortion Effect in Tube Hydroforming of SS304 Bellow ... 39 Experimental Investigation of Tube Drawing Process with Diameter Expansion ... 41 Improvement of Dimensional Precision in Two-step Shear Bending Method Using Mandrels ... 43 An Efficient Method for Analysis of Expanding Hollow Clad Cylinders of Strain Hardening Material ... 45 Suppression of Undesirable Phenomenon of Thin-walled Rectangular Tube in Rotary Draw Bending .... 47 Failure Limit Evaluation of 7xxx Aluminum Alloy Sheet at Elevated Temperatures ... 49 Application of Heat Assisted Dieless Bellows Forming Technology to Various Materials and Dimensions of Tubes... 51 Deformation to Taper Shape by Warm Tube Hydroforming of Small Diameter A1100 Aluminium Tube . 53 Crash Characteristics of Partial-quenched Products by 3 Dimensional Hot Bending and Direct Quench.. 55 New Concept of Hydroforming Process for Microtubes with Large Ratio of Length to Diameter ... 57 Development of Tube Flaring Technology for Large Expansion ... 59 Study on the Joining of Brass Rings and Steel Shafts by Metal Flow Joining Method ... 61 Influence of Internal Pressure and Axial Compressive Displacement on Formability of Small Diameter ZM21 Magnesium Alloy Tube on Warm Tube Hydroforming ... 63 Study on Formability and Fracture of Ti-alloy Tube by Hot Gas Bulging Tests ... 65 One-sided Rubber Bulging Test to Measure Forming Limit Strains of Metal Tube ... 67 Study of Circular and Square Aluminum Alloy Deep Drawing ... 69 Modeling Dynamic Recrystallization of Stainless Steel in the Coupled Crystal Plasticity and Cellular Automata Approach ... 71 Formability Analysis of Fiber Metal Laminates by An Innovative Method in Hydroforming ... 73 Tool Aspects for High Temperature Level Gas Forming ... 75 Flexible diameter reduction of tubes with planetary balls ... 77 Recent Developments in Tube Hydroforming of the MIRDC ... 79 A New Method for Hydroforming of a Variable-diameter Part with Partially Overlapping Tubular Blanks ... 81 Advances in Hydroforming Processes and Applications ... 83 Hydroforming Simulation of Thin Metal Tube ... 85 Advanced CAE Method for Springback Compensation and Process Robustness Analysis of Bent and Hydroformed Parts ... 87 Loading Path Design of Tube Hydroforming Using Movable Dies ... 89 Study of Hydro-reaming and Flanging of Aluminum Tubes ... 91 A Vision-based Fuzzy Control for Semi-dieless Bellows-forming by Local Heating Technique... 93 Effect of Deformation Path in Forming 3D Closed-Section Parts from Sheet Metal ... 95
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Uncertainty in Forming PET-Laminated Tin-Free Steel Sheet to Waving Defect in Lithographic Food Can ... 97 Study of Friction Tests of Strips with Variant Relative Speeds ... 99 Plastic Mechanics of Pipe Drawing with Rotating Die Considering Shear Friction... 101 Press Bending of AZ31 Magnesium Alloy Extruded Tube... 103 Effect of Thickness on Mechanical Joining Between the Aluminum Tube and Sheet by Electromagnetic Expansion ... 105 Development of FEM Analysis Model of Folding Process of Creased Paperboard Using Non-linear
Spring Based Cohesive Zone Model Plus Shear Yield Glue Model ... 107 Hot Gas Bulging of Titanium Alloy Tube Using Current Resistance Heating ... 109
9th INTERNATIONAL CONFERENCE ON TUBE HYDROFORMING (TUBEHYDRO 2019) November 18-21, 2019, Kaohsiung, Taiwan P1
Recent Trends and Perspectives in Tube Forming
Takashi Kuboki
Department of Mechanical and Intelligent Systems Engineering, The University of Electro-Communications,
1-5-1 Chofu Gaoka, Chofu-shi, Tokyo, 182-8585, Japan Keywords: Productivity, Strength, Formability, Flexibility.
Abstract
Tube forming technologies have been contributing to the development of society, and should evolve and have great roles in the future societies, considering the environmental problems. Global warming is a critical problem and the average temperature in the world is still increasing although many countries are tackling to suppress CO2 emissions. The population is another problem, the world would suffer from the aging societies and some countries may suffer from the lack of labor force. The tube forming technology should contribute for solving these problems and realizing sustainable societies.
This paper reviews recent technologies and perspectives in tube forming. The technologies include air forming, rotary forming, bending, micro forming and so on. These technologies are qualitatively evaluated in terms of conflicting characteristics, such as formability, strength, productivity, flexibility and miniaturization. Some technologies are emerging to improve some of the conflicting characteristics at the same time.
Fig. 1 shows air forming processes in terms of strength and formability. Nogiwa et al.
(Sumitomo Heavy Industries, Ltd.) developed an air forming process for commercial use, STAF (Steel Tube Air Forming), which utilizes the air pressure more effectively for bulging tubes against the die walls [1]. This method will decrease the number of processes from four to two, compared to hot stamping of sheet metals, for manufacturing frames of vehicles.
Figure 1: Air forming in strength after deformation and formability.
Figure 2: Forming for diameter-reduction in productivity and formability.
Fig. 2 qualitatively shows forming processes for reducing diameters of tubes in terms of productivity and formability. While productivity is very high for press nosing, formability is very low. While formability is very high for spinning, productivity is very low. Arai et al.
developed a spinning process, which reduced the tube diameter in an asymmetric manner by synchronizing the rollers position with the rotation angle of the tube [2]. Other rotary forming processes, which travel tools once, were proposed. They are "orbital rotary forming" by
31
Kitazawa et al. [3] and "RDR-reduction (Relieved Die Rotary reduction, rotary reduction with relieved die)" by Kuboki et al. [4]. These rotary forming have intermediate contact areas between press nosing and spinning.
Bending processes are reviewed in terms of flexibility. Institut für Umformtechnik und Leichtbau (IUL) developed TSS (Torque Superposed Spatial bending) bending, which can bend a tube in a 3-dimensional manner while twisting the tube [5]. One of the unique points of the process is that it uses closed-loop control for controlling bending radius. The target moment is set instead of the target bending radius. Nippon Steel Co. developed 3DQ (3 Dimensional Hot Bending and Quench) [6]. The bending point of the tube is locally heated by the induction heater while the end of tube is supported by the robotic manipulator.
Miniaturization is another key word, and it is needed for manufacturing parts for medical and electronic field. Kuboki et al. developed a method for fabricating the spring with a cross section of high rectangle ratio, using a tube as a raw material [7]. The fabricated spring is expected to use for downsizing the diameter of surgical manipulators leading to the alleviation of burden on patients. Shirayori [8] and S. Mori [9] have been trying to develop hydroforming processes for fabrication of cross-shaped tubes with diameters of 8.0 – 0.5 mm. Furushima et al.
have been improving dieless-drawing [10]. This method reduces the cross section of a hollow tube in a homothetic manner. Once a complicated cross section is fabricated in a macro scale, the same complicated structural cross section can be realized in a micro scale by this method.
The developing computer technology and informatics science will boost the tube forming technology. Digitalization of experts' knowledge will help the next generation to realize the sustainable societies. Kuriyama et al. applied design-mapping technology for structuring engineers' knowledge for accumulating technical knowledge for conveying it to the next generation [11]. The availability of multi-scale analyses [12] and multi-physics simulations [13] will be improved, and the simulations would help the tube forming technologies to develop rapidly.
REFERENCES
[1] Nogiwa, K., Ishizuka, M., Ide, A., Ueno, N., 2017, The Proceedings of the 68th Japanese Joint Conference for the Technology of Plasticity, pp. 411-412, in Japanese.
[2] Oezer, A., Sekiguchi, A., Arai, H., 2012, Experimental implementation and analysis of robotic metal spinning with enhanced trajectory tracking algorithms, Robotics and Computer-Integrated Manufacturing, 28-4, pp. 539-550.
[3] Kitazawa, K., 2015, Prevention of curling in orbital rotary flanging of 1050 and 5052 aluminum alloy tube-ends, Journal of Japan Institute of Light Metals, 65-1, pp. 2-6, in Japanese.
[4] Kuboki, T., Abe, M., Yamada, Y., Murata, M., 2015, Flexible rotary reduction of tube tips by dies with relief surfaces for attaining high forming limit and productivity, CIRP Annals - Manufacturing Technology, 64/1, pp. 269-272.
[5] Chatti, S., Hermes, M., Tekkaya, A., Kleiner, M., 2010, The new TSS bending process: 3d bending of profiles with arbitrary cross-sections, CIRP Annals - Manufacturing Technology, 59/1, pp. 315-318.
[6] Shimada, N., Tomizawa, A., Kubota, H., Mori, H., Hara, M., Kuwayama, S., 2014, Development of three-dimensional hot bending and direct quench technology, Procedia Engineering, 81, pp. 2267-2272.
[7]-[13] are omitted.
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9th INTERNATIONAL CONFERENCE ON TUBE HYDROFORMING (TUBEHYDRO 2019) November 18-21, 2019, Kaohsiung, Taiwan P2
New Processes and Applications of Rapid Hot Gas Forming of Light-alloy Tubes
Zhubin He1, Xiaobo Fan1, Song Yang2, Changqin Wang3, Gang Liu4 and Shijian Yuan1,4*
1 School of Mechanical Engineering, Dalian University of Technology, Dalian 116024, China
2 BAIC Group Off-road Vehicle Co., Ltd., Beijing 101300, China
3 Giant (China) Co., Ltd., Kunshan 215300, China
4 National Key Lab for Precision Hot Processing of Metals, Harbin Institute of Technology, Harbin 150001, China
Keywords: Rapid hot gas forming, Elevated temperature, Hydroforming, Light-alloy tube.
Abstract
Thin-walled components with complex curved-shapes are very important in the industries of aerospace, aircraft and automotive. The aerodynamic performance, the launch capability, and the fuel efficiency of these transportation structures are mainly decided by the accuracy of shapes and dimensions of the thin-walled components. In the development of advanced transportaion industries, many new integral structures with large dimensions and complex shapes have been designed, which has consequently brought great challenges for the manufacturing techniques.
In aerospace and automotive industries, aluminum alloys are widely used to meet the need for light-weight structures. However, further application is limited by their poor formability and high springback at room temperature. In general, aluminum alloys exhibit good formability and low springback at elevated temperatures. Hence, different hot forming techniques have been developed to solve these critical problems [1-3]. Hot Metal Gas Forming (RHGF) or Rapid Hot Gas Forming (RHGF) is an advanced forming method for such components, during which the high pressure gas is used to form the preheated material [4].
In this paper, the principle of RHGF and its characteristics is given first. Then, the state of the art and some new developments of RHGF in forming mechanism, process, equipment, are presented. The principle of dual-hardening of both strain and strain rate(see Fig.1), the tailored heating method of tubular blank and die, and the hot forming and in-die quenching of tube, are discussed. Equipments for mass production and typical industrial applications of RHGF for the manufacturing of tubular parts in aerospace and automotive industries are presented (see Fig.2).
It should be pointed out that the forming mechanism, the heating method, the friction behavior and lubrication in RHGF, mainly depends on the forming temperature and forming speed, which consequently makes it difficult to determine the optimal process parameters.
From another point of view, when some or all the new process variables in RHGF can be optimized and controlled, more opportunities are created meanwhile for manufacturing of thin-walled complex components.
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(a) Dual-hardening (b) Microstructure evaluation Figure 1: Illustration of dual-hardening effect and its mechanism.
Figure 2: Tubular parts formed by RHGF.
REFERENCES
[1] H. Karbasian, A.E. Tekkaya, 2010, A review on hot stamping, Journal of Materials Processing Technology, 210, pp. 2103-2118.
[2] A. Paul, M. Strano, 2016, The influence of process variables on the gas forming and press hardening of steel tubes, Journal of Materials Processing Technology, 228, pp. 160-169.
[3] O. E. Fakir, L.L. Wang, D. Balint, J. P. Dear, J.G. Lin, T. A. Dean, 2014, Numerical study of the solution heat treatment, forming, and in-die quenching (HFQ) process on AA5754, International Journal of Machine Tools & Manufacture, 87, pp. 39-48.
[4] X.B. Fan, Z.B. He, P. Lin, S.J. Yuan, 2016, Microstructure, texture and hardness evolutions of Al-Cu-Li alloy sheet during hot gas forming with integrated heat treatment, Materials &
Design, 94, pp. 449-456.
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9th INTERNATIONAL CONFERENCE ON TUBE HYDROFORMING (TUBEHYDRO 2019) November 18-21, 2019, Kaohsiung, Taiwan P3
A Study on Tube-Hydroformed Automotive Twist Beam Design
Cheng-Ting Yeh1, Guan-Cheng Chen1 and Fuh-Kuo Chen1,*
1 Department of Mechanical Engineering, National Taiwan University, Roosevelt Rd., Taipei 106, Taiwan, R.O.C.
Keywords: Tube-hydroformed twist beam, Strength analysis, Formability, Finite element analysis.
Abstract
In recent years, due to the arising of the environment protection, the concept of energy saving and carbon reduction has become an important issue in industrial development. In order to achieve the target of energy saving and carbon reduction, the lightweight structure design has been an important task for the automotive industry. Twist beam rear suspension system is then widely adopted by the automotive industry [1]. It is an effective method to replace traditional stamping technology with tube-hydroforming technology [2], and advanced high-strength steel is also preferred to produce light weight and high strength automotive structure parts. In this paper, more than twenty geometric parameters were designed to parameterize the overall structure of a tube-hydroformed twist beam. With those parameterized models, we are able to investigate the effects of parameters on the rolling stiffness and structure strength of a rear suspension system with a twist beam, as shown in Figure 1. An optimization analysis on the geometry of the transition zone in the twist beam, as shown in Figure 2, was also conducted so that the pattern of maximum stress distribution can be figured out and further to be reduced for meeting the strength and stiffness requirements. At the same time, the formability of an advanced high-strength steel twist beam has also been considered. A novel design of a pre-forming die surface with an inserted mandrel to reduce the die-contact distance between hydroformed part and die surface was proposed in this paper. The thinning defect could also be improved with the proposed die design. An actual advanced high-strength steel twist beam was then successfully produced following the beam-shape design and manufacturing process proposed in this paper. The agreement between the experimental data measured from the actual twist beam and those predicted by the finite element simulation results validates the twist beam design proposed in this paper.
Figure 1: A rear suspension system with twist beam design.
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Figure 2: Geometry of the transition zone in a twist beam.
REFERENCES
[1] Chen J., Jiang Y., Qin M., Hao W., Chang YP. and Jin L., 2015, “CAD/CAE and Optimization of a Twist Beam Suspension System”, SAE Technical Paper, pp. 1-6.
[2] Kim J., Oh J., Choi H., 2010, The design and performance evaluation of hydroformed tubular torsion beam axle, AIP Conference Proceedings, 1252, pp. 397-402.
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9th INTERNATIONAL CONFERENCE ON TUBE HYDROFORMING (TUBEHYDRO 2019) November 18-21, 2019, Kaohsiung, Taiwan P4
Ductile Fracture of Aluminum Tubes for Hydroforming Applications
Madhav Baral1 and Yannis P. Korkolis2,*
1 Department of Mechanical Engineering, University of New Hampshire, 33 Academic Way, Durham, NH 03824, USA
2 Department of Integrated Systems Engineering, The Ohio State University, 1971 Neil Avenue, Columbus, OH 43210, USA
Keywords: Aluminum tube, Ductile fracture, Anisotropy, Hydroforming.
Abstract
Ductile fracture is one of the main modes of failure in tube hydroforming. The formability of a tube is often limited by low ductility and/or limited empirical knowledge about the fracture behavior. Despite decades-old research on fracture, challenges remain, especially when considering the peculiarities of the tubular geometry and multiaxial, non-proportional stress states during hydroforming. In this work, the fracture behavior of AA6260-T4 tubes is assessed using the experiments of the tubes conducted under axial force and internal pressure without a die (i.e., free-inflation) subjected to both proportional and non-proportional loads to failure [1, 2]. The results are used to model the plastic anisotropy of the material by two non-quadratic anisotropic yield functions – Yld2000-2D and Yld2004-3D [3]. The hardening behavior is identified using uniaxial tension tests on strips cut from the axial direction of the tube.
The ductile fracture behavior is probed using a combined experimental-numerical approach. This approach is pursued because the direct measurement of fracture parameters in the tube experiments is impossible due to the fracture perhaps initiating inside the wall-thickness. The finite element (FE) models of the experiments are generated using the material modeling framework described above, along with a rate-independent, associated flow rule and isotropic hardening. Solid elements are used to probe the local stress and strain fields at the onset of fracture at the interior of the tube, and thus establish the fracture locus of the material. These elements are computationally expensive, so they are used to mesh only the region were fracture is expected to occur. The rest of the tube is modeled with shell elements, and a surface-based shell-to-solid coupling is used to join the two regions of the finite element model as shown in Fig. 1. Only one quarter of the tube is modeled due to symmetry.
Figure 1: Finite element model of the tube with axial imperfection.
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The predictions of the FE models are compared to the behaviors observed during the tube experiments, e.g., the nominal stress-strain responses for each stress path, defined as the ratio (α) of axial to circumferential stress. In addition, the performance of these models is obtained by comparing the nominal strain paths from the experiments and the corresponding simulations up to the load maximum as shown in Fig. 2. These comparisons are done to establish the fidelity of the numerical models. The FE models are then used to probe the loading paths at the critical material point to determine the fracture locus of the tube. The proportionality of the loading paths is important as fracture is path-dependent [4]. The same combined experimental-numerical approach is used to probe the path-dependence of the fracture locus.
While these results replicate the free-inflation experiments well, they are insufficient for capturing fracture during the hydroforming process, where the tube is confined within a die during inflation. This confinement stabilizes the deformation and causes a different stress triaxiality than in the free-inflation experiments above. This work will discuss some of the challenges when attempting to use free-inflation results to predict fracture in confined-inflation, as in tube hydroforming.
Figure 2: Comparison of the FE and experimental engineering paths for nine loading paths.
REFERENCES
[1] Korkolis, Y.P., Kyriakides, S., 2008, Inflation and burst of anisotropic aluminum tubes for hydroforming applications, International Journal of Plasticity, 24(3), pp. 509-543.
[2] Korkolis, Y. P., & Kyriakides, S., 2009, Path-dependent failure of inflated aluminum tubes, International Journal of Plasticity, 25(11), pp. 2059-2080.
[3] Barlat, F., Aretz, H., Yoon, J.W., Karabin, M.E., Brem, J.C., Dick, R.E., 2005, Linear transformation-based anisotropic yield functions, International Journal of Plasticity, 21(5), pp. 1009-1039.
[4] Kuwabara, T., Yoshida, K., Narihara, K., Takahashi, S., 2005, Anisotropic plastic deformation of extruded Al alloy tube under axial forces & internal pressure, International Journal of Plasticity, 21(1), pp. 101-117.
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9th INTERNATIONAL CONFERENCE ON TUBE HYDROFORMING (TUBEHYDRO 2019) November 18-21, 2019, Kaohsiung, Taiwan T1-1
Shape Distortion Effect in Tube Hydroforming of SS304 Bellow
Neranuch Usamith1 and Purit Thanakijkasem1,*
1Division of Materials Technology, School of Energy, Environment and Materials King Mongkut’s University of Technology Thonburi
126 Pracha Uthit Rd., Bangkok 10140, Thailand
Keywords: Tube hydroforming, Shape distortion, SS304 bellow, Springback.
Abstract
This work was aimed to study tube hydroforming of SS304 bellows. A recent review on hydroforming can be seen in [1]. A springback effect in hydroforming process of SS304 was discussed by using Hill theory in [2]. The tube material in this work was SS304 with the initial thickness of 0.4 mm. Two shapes of the bellows were studied. In addition, different processing conditions were explored to optimize the process. Finite element analysis was conducted to study the process. The applied pressure and the gap spacing dominantly affected the formability.
A significant shape distortion was found. The main source of shape distortion is springback in the material. Two different material models were applied to observe the prediction effectiveness in springback prediction. The simulation agreed well with the experiment
The main variables were the part shape, i.e., Shape1 = S1 and Shape2 = S2, and the processing conditions, i.e., the applied pressure (P) and the gap spacing (G). For formability issue, both shapes were observed at different pressures and gaps as shown in Fig. 1.
(a) (b)
(c) (d)
Figure 1: Formability from G = 5.96 mm at (a) S1 and P=10 MPa, (b) S1 and P=15 Mpa, (c) S2 and P=10 MPa, and (d) S2 and P=15 MPa.
To observe the effect of the gap spacing, P = 15 MPa was chosen because a lower pressure was typically desired in real manufacturing. Fig. 2 showed SP from MAT37 and MAT125 for S1 and S2 at G = 5.96, 6.5, 7.0, 7.5, 8.0 mm. The estimated SP from MAT125 was larger than that from MAT37. Shape2 caused less sprinback amount when compared to Shape1.
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Tube hydroforming (THF) process can successfully produce the bellow of interest with the right combination of the processing conditions through analysis and design with FEA. FEA as a part of CAE is an important tool to explore the forming window. Springback is an important problem needed to be solved for products under a high commitment. For this bellow, a kinematic model like YU is needed to analyze and design a proper THF process.
Figure 2: Springback from P=15 MPa and G = 5.96, 6.5, 7.0, 7.5, 8.0 mm.
REFERENCES
[1] Lee M.G., Korkolis Y.P., Kim J.H., 2015, Recent developments in hydroforming technology, Journal of Engineering Manufacture, 229 (4), pp. 572-596.
[2] Sun Z., Lang L., 2017, Effect of stress distribution on springback in hydroforming process, The International Journal of Advanced Manufacturing Technology, 93, pp. 2773-2782.
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9th INTERNATIONAL CONFERENCE ON TUBE HYDROFORMING (TUBEHYDRO 2019) November 18-21, 2019, Kaohsiung, Taiwan T1-2
Experimental Investigation of Tube Drawing Process with Diameter Expansion
Shohei Kajikawa1,*, Hikaru Kawaguchi1, Takashi Kuboki1, Isamu Akasaka2, Yuzo Terashita2 and Masayoshi Akiyama3
1 Department of Mechanical and Intelligent Systems Engineering, The University of Electro-Communications,
1-5-1 Chofu Gaoka, Chofu-shi, Tokyo, 182-8585, Japan
2 Miyazaki Machinery Systems Co., Ltd., 1 Nii, Kaizuka-shi, Osaka, 597-8588, Japan
3 Akiyama Mechanical Engineering Consulting,
2-7-306 Tanaka Sekiden-cho, Sakyo-ku, Kyoto-shi, Kyoto, 606-8203, Japan Keywords: Drawing, Flaring, Tube expansion, Thickness reduction.
Abstract
Thin-walled tubes, which is used for various machine components, contribute reduction in size and weight of various machines for environmental protection. The thin-walled tube is manufactured from rather thick-walled raw tubes by multi-pass drawing which is the conventional cold working of tube, and determines many properties of the tube [1]. However, many drawing passes are needed for manufacturing very thin-walled tubes. This is because the tube tends to fracture in the drawing process when the thickness reduction is too large for one drawing pass. Therefore, production cost increases with the increase of the number of the drawing passes.
This paper proposes a tube drawing method with diameter expansion for manufacturing thin-walled tubes effectively. In the proposed method, the tube end is flared by plug pushing into the tube in first process, and then the tube is expanded by drawing the plug in axial direction while the flared end was chucked in second process. Because the tube wall stretches biaxially in axial and hoop direction, the thickness should be reduced effectively compared to the conventional drawing with the diameter shrink. In this study, forming limit, thickness reduction and deviation were investigated by a series of experiments in the proposed method.
At first, effects of the tube material and flaring shape on maximum flaring ratio Ef_max were
0 0.2 0.4 0.6 0.8 1
0 1 2 3 4 5
Maximum flaring ratio Ef_max
Initial thickness t0[mm]
AA1070 (Taper)
STKM13C (Taper) STKM13C (Taper-straight)
Buckling Crack α
dp d0
di0t0
Tube
Plug Holder
dif
(a) Set-up
(b) Flaring shape
dp≒dif
Only taper Taper-straight ls
(c) Defect mode and maximum flaring ratio Ef_max Figure 1: Investigation about effect of tube material and flaring shape on maximum flaring
ratio Ef_max.
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investigated by the experiment as shown in Fig. 1. Initial diameter d0 of the tube was 30 mm, and half angle α of the plug was 12°. Flaring shapes were two types, which were only taper and taper-straight, as shown in Fig. 1 (b). Taper-straight shape was needed for the next drawing process, and the plug pushed until the straight length ls achieved to 20 mm in the case of taper-straight. Ef_max was defined as a maximum value before defect occurrence. Fig. 1 (c) shows the defect mode and Ef_max. The defect mode changed by the tube material. Buckling, which appeared at the cylinder portion near the holder, was easy to occur when an aluminum tube of AA1070 was used. Crack, which appeared at the flared edge, occurred when a steel tube of STKM13C was used. Ef_max increased with an increase in the tube initial thickness t0. In addition, Ef_max of taper-straight shape was lower than that of only taper shape. This is because the tube wall bent between the taper and the straight portion, and then the outside of the tube wall was stretched biaxially in the axial and the hoop direction.
The experiment of the expansion drawing was carried out using the tube which was flared to the taper-straight shape as shown in Fig. 2 (a). Initial diameter d0 and half angle α of the plug were 30 mm and 12°. It was possible to produce the thin-walled tubes successfully, but the tube cracked due to biaxial stretching in axial and hoop direction when the expansion ratio Ed was too large as shown in Fig. 2 (b). Fig. 2 (c) shows the effect of Ed on the thickness reduction γ and thickness deviation λ of the drawn tube. γ increased with the increase in Ed. Maximum thickness reduction γ_max were 0.29 at the maximum expansion ratio Ed_max of 0.31 when AA1070 was used, and this value of γ_max was higher than that of the conventional drawing with diameter shrink [2]. The increase in λ by the drawing was small in the range of Ed=0~0.23, but λ drastically increased when the local thinning appeared at the tube wall due to too large expansion such as Ed=0.31. Therefore, Ed should be set appropriately for producing the tube which λ is low.
Figure 2: Investigation about effect of expansion ratio Ed on thickness reduction γ and deviation ratio λ in drawing.
REFERENCES
[1] Kuboki, T., Tasaka, S., Kajikawa, S., 2017, Examination of working condition for reducing thickness variation in tube drawing with plug, COMPLAS XIV, Conference proceedings.
Barcelona, pp. 63-71.
[2] The Japan Society for Technology of Plasticity, 2017, Drawing -Drawing Technologies for Bar, Wire and Tube-, Corona Publishing, Tokyo, in Japanese.
Plug Shaft
Chuck Core
Flared portion dp
α
Tube t
(a) Schematic diagram of drawing
Success Crack
(b) Appearance of typical drawn tube
0 0.1 0.2 0.3
0 0.1 0.2 0.3 0.4
Thickness reduction ratio γ Thickness deviation ratio λ
Expansion ratio Ed AA1070, γ
STKM13C , γ
AA1070, λ
STKM13C, λ
(c) Thickness reduction and deviation of tube
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9th INTERNATIONAL CONFERENCE ON TUBE HYDROFORMING (TUBEHYDRO 2019) November 18-21, 2019, Kaohsiung, Taiwan T1-3
Improvement of Dimensional Precision in Two-step Shear Bending Method Using Mandrels
Takashi Kuboki1,*, Daisuke Kusuda1, Shohei Kajikawa1, Takahiro Noguchi2 and Kazuaki Adachi2
1 Department of Mechanical and Intelligent Systems Engineering, The University of Electro-Communications,
1-5-1 Chofu Gaoka, Chofu-shi, Tokyo, 182-8585, Japan
2 Komatsu, Ltd., 3-1-1, Ueno, Hirakata-shi, Osaka, 573-1011, Japan Keywords: Shear bending, Tube bending, Mandrel, Copper.
Abstract
This paper shows proper working conditions for improvement of dimensional precision in
"two-step shear bending using mandrels", which has recently been proposed by the authors.
Two-step shear bending was invented based on a conventional shear bending. The conventional method is one-step shear bending, and uses a pair of mandrels for suppression of tube collapse by supporting the inner tube surface [1-3]. One-step shear bending can bend a tube at an excessively small bending radius, which is almost zero at the tube neural planes. However, it was too small for fluids to flow smoothly, although the smallness of the bending radius contributes to the space conservation when the tubes are used in industrial machines or heat exchanges. The bending radius, which is determined by the mandrel shape, is inevitably small as the mandrel radius cannot be enlarged due to the small space inside the tube.
Two-step shear bending has been invented for solving the problem of the excessive smallness of the bending radius. Two-step shear bending is composed of two steps of forming as shown in Fig. 1. The first step creates a space between the pair of mandrels. The second step changes mandrels and insert them into the created space. The created space is larger than the original tube inner space, and then the tip shape of the second mandrels can be enlarged. The shape of the exchanged mandrels is transferred to the tube shape. As a result, the bending radius can be enlarged around 0.5 times the tube diameter at the tube neutral plane. It had been found that two-step shear bending successfully bend tubes at an appropriately small bending radius.
However, the results still leaves the dimensional precision to be considered.
This paper shows proper working conditions for improvement of dimensional precisions, focusing upon the timing for changing the steps and the effect of the die corner radius. The ovality and warp of the deformed part basically tends to be large, when compared to the one-step shear bending. A series of finite element analyses and laboratory experiments were carried out for the improvement. The following results were obtained. The circularity was improved by the delay of the changing timing from the first to the second step, as long as the 2nd-step die stroke still remains enough for the transfer of the mandrel-shape to the tube shape.
Further improvement of the circularity was possible by the increase of die corner radius, as long as the crack or large wrinkle do not occur. The effect of the changing time of the steps using a large die corner radius is shown in Fig. 2. The ovality was levelled and the circularity was successfully improved.
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