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. 2022 Feb 12;3(4):592-601.
doi: 10.1016/j.fmre.2022.01.024. eCollection 2023 Jul.

Characterization of mechanical properties for tubular materials based on hydraulic bulge test under axial feeding force

Bin Zhang  1   2 , Benny Endelt  1 , Karl Brian Nielsen  3   4
Affiliations

Characterization of mechanical properties for tubular materials based on hydraulic bulge test under axial feeding force

Bin Zhang et al. Fundam Res. .

Abstract

A T-shape tube hydraulic bulge test under axial feeding force is carried out to characterize the mechanical properties of EN AW 5049-O and 6060-O aluminium alloys. The punch displacement, T-branch height and axial compressive force are recorded online during the experiment. An intelligent inverse identification framework combining the finite element method and numerical optimization algorithm is developed to determine material parameters by fitting simulated results to the experimental data iteratively. The identified constitutive parameters using the inverse modelling technique are compared with those determined by the theoretical analysis and uniaxial tensile test. The comparison shows that the predicted bulge height and punch force based on the material parameters obtained by the three methods are different and the inverse strategy produces the smallest gap between numerical and experimental values. It is possible to conclude that the hydraulic bulge test can be applied to characterize the stress-strain curve of tubular materials at the large strain scope, and the automatic inverse framework is a more accurate post-processing procedure to identify material constitutive parameters compared with the classical analytical model.

Keywords: Constitutive model; Hydraulic bulge test; Intelligent optimization; Parameter identification; Tubular material.

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Conflict of interest statement

The authors declare that they have no conflicts of interest in this work.

Figures

None
Graphical abstract
Fig. 1
Fig. 1
Experimental setup for tube hydraulic bulge test.
Fig. 2
Fig. 2
Dies and axial punches in experimental tools.
Fig. 3
Fig. 3
Flow chart of the overall electrical system for hydraulic press.
Fig. 4
Fig. 4
Approximate loading path for 5049-O and 6060-O aluminium alloy in hydraulic bulge test.
Fig. 5
Fig. 5
An illustration of how tensile specimens are cut from the tested tube at different circumferential positions.
Fig. 6
Fig. 6
Schematic diagram of T-shape tube hydraulic bulge test.
Fig. 7
Fig. 7
Illustration of the flow chart of inverse strategy utilized in parameter identification based on hydraulic bulge test.
Fig. 8
Fig. 8
FE model for the T-shape tube hydraulic bulge process.
Fig. 9
Fig. 9
True stress-strain curve determined by tensile test for 5049-O aluminium alloy.
Fig. 10
Fig. 10
True stress-strain curve determined by tensile test for 6060-O aluminium alloy.
Fig. 11
Fig. 11
Hydro bulged specimens before and after test for aluminium alloy 5049-O and 6060-O.
Fig. 12
Fig. 12
Iteration history of two design variables.
Fig. 13
Fig. 13
Iteration history of the objective function and its gradient.
Fig. 14
Fig. 14
Comparison of FE outputs and experimental data of punch displacement versus T-branch height for 5049-O aluminium.
Fig. 15
Fig. 15
Comparison of FE outputs and experimental data of punch displacement versus T-branch height for 6060-O aluminium.
Fig. 16
Fig. 16
Comparison of FE outputs and experimental data of punch displacement versus axial feeding force for 5049-O aluminium.
Fig. 17
Fig. 17
Comparison of FE outputs and experimental data of punch displacement versus axial feeding force for 6060-O aluminium.
Fig. 18
Fig. 18
Different mean errors obtained by three methods for 5049-O aluminium.
Fig. 19
Fig. 19
Different mean errors obtained by three methods for 6060-O aluminium.
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