Kenneth I. Johnson

Analysis of Tube Hydroforming by Means of an Inverse Approach

This paper presents a computational tool for the analysis of freely hydroformed tubes by means of an inverse approach. The formulation of the inverse method developed by Guo et al. is adopted and extended to the tube hydrofoming problems in which the initial geometry is a round tube submitted to hydraulic pressure and axial feed at the tube ends (end-feed). A simple criterion based on a forming limit diagram is used to predict the necking regions in the deformed workpiece. Although the developed computational tool is a stand-alone code, it has been linked to the Marc finite element code for meshing and visualization of results. The application of the inverse approach to tube hydroforming is illustrated through the analyses of the aluminum alloy AA6061-T4 seamless tubes under free hydroforming conditions. The results obtained are in good agreement with those issued from a direct incremental approach. However, the computational time in the inverse procedure is much less than that in the incremental method.

Analysis of Tube Free Hydroforming Using an Inverse Approach With FLD-Based Adjustment of Process Parameters

This paper employs an inverse approach (IA) formulation for the analysis of tubes under free hydroforming conditions. The IA formulation is derived from that of Guo et al. established for flat sheet hydroforming analysis using constant strain triangular membrane elements. At first, an incremental analysis of free hydroforming for a hot-dip galvanized (HG/Z140) DP600 tube is performed using the finite element Marc code. The deformed geometry obtained at the last converged increment is then used as the final configuration in the inverse analysis. This comparative study allows us to assess the predicting capability of the inverse analysis. The results will be compared with the experimental values determined by Asnafi and Skogsgardh. After that, a procedure based on a forming limit diagram (FLD) is proposed to adjust the process parameters such as the axial feed and internal pressure. Finally, the adjustment process is illustrated through a re-analysis of the same tube using the inverse approach

Accuracy issues in modeling superplastic metal forming

The utility of finite element modeling in optimizing superplastic metal forming is dependent on accurate representation of the material constitutive behavior and the frictional response of the sheet against the die surface. This paper presents work conducted to estimate the level of precision that is necessary in constitutive relations for finite element analysis to accurately predict the deformation history of actual SPF components. Previous work identified errors in SPF testing methods that use short tensile specimens with gauge length-to-width ratios of 2:1 or less. The analysis of the present paper was performed to estimate the error in predicted stress that results from using the short specimens. Stress correction factors were developed and an improved constitutive relation was implemented in the MARC finite element code to simulate the forming of a long, rectangular tray. The coefficient of friction in a Coulomb friction model was adjusted to reproduce the amount of material draw-in observed in the forming experiments. Comparisons between the finite element predictions and the forming experiments are presented.

An in situ tensile test apparatus for polymers in high pressure hydrogen

Degradation of material properties by high-pressure hydrogen is an important factor in determining the safety and reliability of materials used in high-pressure hydrogen storage and delivery. Hydrogen damage mechanisms have a time dependence that is linked to hydrogen outgassing after exposure to the hydrogen atmosphere that makes ex situ measurements of mechanical properties problematic. Designing in situ measurement instruments for high-pressure hydrogen is challenging due to known hydrogen incompatibility with many metals and standard high-power motor materials such as Nd. Here we detail the design and operation of a solenoid based in situ tensile tester under high-pressure hydrogen environments up to 42 MPa (6000 psi). Modulus data from high-density polyethylene samples tested under high-pressure hydrogen at 35 MPa (5000 psi) are also reported as compared to baseline measurements taken in air.

V1.6 Development of Advanced Manufacturing Technologies for Low Cost Hydrogen Storage Vessels

The goal of this project is to develop an innovative manufacturing process for Type IV high-pressure hydrogen storage vessels, with the intent to significantly lower manufacturing costs. Part of the development is to integrate the features of high precision AFP and commercial FW. Evaluation of an alternative fiber to replace a portion of the baseline fiber will help to reduce costs further.

Hydrogen Tank Project Q2 Report - FY 11

Quarterly report that represents PNNLs results of HDPE, LDPE, and industrial polymer materials testing. ASTM D638 type 3 samples were subjected to a high pressure hydrogen environment between 3000 and 4000 PSI. These samples were tested using an instron load frame and were analyzed using a proprietary set of excel macros to determine trends in data. The development of an in-situ high pressure hydrogen tensile testing apparatus is discussed as is the stress modeling of the carbon fiber tank exterior.

Characterization of Plastically Deformed Steel Utilizing EMAT Ultrasonic Velocity Measurements

There is a desire to characterize plastically deformed regions in structures to monitor their integrity. Of particular importance is the accurate prediction of the lifetime of damaged pipelines due to outside force. In order to accurately predict the remaining life it is essential to accurately determine the degree stress and strain in the damaged region for input into fracture mechanics models. Currently, determination of the degree of stress and strain in damaged regions utilizing ultrasonic velocity measurements is complicated by the inherent texture in the materials and the difficulty in separating these effects from the stress and strain contributions. We will report ultrasonic velocity measurements on plastically deformed steel specimens to elucidate the state of damage. Specifically, we have found the shear wave birefringence and SH wave velocity are sensitive to the degree of plastic deformation. Ultrasonic results will be compared with finite element modeling calculation of the stress and strain ...