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Analysis of thickness variation and stress state in hydroforming of complex T-shaped tubular part of nickel-based superalloy

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Abstract

Stress states on a multi-branch tubular part are the most complicated change in all types of hydroforming process, which result in severe variation of thickness. In this paper, an experimental and numerical research was conducted on a multi-step hydroforming process including intermediate annealing treatment to obtain effect of stress state on the thickness variation of a superalloy GH4169 complex T-shaped tubular part with expanded diameter, which corresponds to a real product used in aerospace industry. The material flow behavior at typical points on hydroformed tube blank was first analyzed. Then, the thickness variation on the hydroformed GH4169 tube blanks was discussed in every step. It is shown that the materials have different flow directions to form the side branch, where the thickness is always thinned during the four-step hydroforming process. Large axial feeding induces a continuous thickening between transition areas and tube ends. The thickness invariant dividing line in the side branch zone moves toward the tube ends with forming going on. However, in the hemisphere zone, it moves slightly towards the center of the side branch. Moreover, the stress states at three typical positions, as well as their effect on the thickness variation, were analyzed based on a sequential correspondence law between stress and strain components. On this basis, the mechanism of thickening in the left transition area, thinning at the top of side branch and thickness variation at the hemispheric pole was revealed. These results are very important for obtaining the thickness distribution of a complex T-shaped tubular part in multi-step hydroforming, and revealing the thickness variation mechanism by using engineering plasticity theory.

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Acknowledgements

This investigation is financially supported by the National Natural Science Foundation of China (Number U1937205, 51805357), the Project Funded by China Postdoctoral Science Foundation (Number 2020M670907), and the Project Supported by Heilongjiang Postdoctoral Foundation (Number LBH-Z20017). The authors wish to express their gratitude to the funding support. The authors also would like to thank for the contributions of Xiaohui Lu to the experiments.

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Authors and Affiliations

  1. National Key Laboratory for Precision Hot Processing of Metals, Harbin Institute of Technology, Harbin, 150001, China

    Xiao-Lei Cui & Shijian Yuan

  2. School of Materials Science and Engineering, Harbin Institute of Technology, Harbin, 150001, China

    Xiao-Lei Cui

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  1. Xiao-Lei Cui
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  2. Shijian Yuan
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Correspondence to Shijian Yuan.

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Cui, XL., Yuan, S. Analysis of thickness variation and stress state in hydroforming of complex T-shaped tubular part of nickel-based superalloy. Archiv.Civ.Mech.Eng 21, 111 (2021). https://doi.org/10.1007/s43452-021-00263-x

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  • DOI: https://doi.org/10.1007/s43452-021-00263-x

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