This paper presents an extended stress-based forming limit curve (XSFLC) that can be used to predict the onset of necking in sheet metal loaded under non-proportional load paths, as well as under three-dimensional stress states. The conventional strain-based FLC is transformed into the stress-based FLC advanced by Stoughton (1999, Int. J. Mech. Sci., 42, pp. 1–27). This, in turn, is converted into the XSFLC, which is characterized by the two invariants, mean stress and equivalent stress. Assuming that the stress states at the onset of necking under plane stress loading are equivalent to those under three-dimensional loading, the XSFLC is used in conjunction with finite element computations to predict the onset of necking during tubular hydroforming. Hydroforming of straight and pre-bent tubes of EN-AW 5018 aluminum alloy and DP 600 steel are considered. Experiments carried out with these geometries and alloys are described and modeled using finite element computations. These computations, in conjunction with the XSFLC, allow quantitative predictions of necking pressures; and these predictions are found to agree to within 10% of the experimentally obtained necking pressures. The computations also provide a prediction of final failure location with remarkable accuracy. In some cases, the predictions using the XSFLC show some discrepancies when compared with the experimental results, and this paper addresses potential causes for these discrepancies. Potential improvements to the framework of the XSFLC are also discussed.
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e-mail: worswick@lagavulin.uwaterloo.ca
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January 2007
Technical Papers
Prediction of Necking in Tubular Hydroforming Using an Extended Stress-Based Forming Limit Curve
C. Hari Manoj Simha,
C. Hari Manoj Simha
Department of Mechanical Engineering,
University of Waterloo
, Waterloo, ON, Canada, N2L 3G1
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Javad Gholipour,
Javad Gholipour
Institute for Aerospace Research,
National Research Council
, Aerospace Manufacturing Technology Center, 5145 Decelles Avenue, Campus of the University of Montreal, Montreal, PQ, Canada H3T 2B2
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Alexander Bardelcik,
Alexander Bardelcik
Department of Mechanical Engineering,
University of Waterloo
, Waterloo, ON, Canada, N2L 3G1
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Michael J. Worswick
Michael J. Worswick
Department of Mechanical Engineering,
e-mail: worswick@lagavulin.uwaterloo.ca
University of Waterloo
, Waterloo, ON, Canada, N2L 3G1
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C. Hari Manoj Simha
Department of Mechanical Engineering,
University of Waterloo
, Waterloo, ON, Canada, N2L 3G1
Javad Gholipour
Institute for Aerospace Research,
National Research Council
, Aerospace Manufacturing Technology Center, 5145 Decelles Avenue, Campus of the University of Montreal, Montreal, PQ, Canada H3T 2B2
Alexander Bardelcik
Department of Mechanical Engineering,
University of Waterloo
, Waterloo, ON, Canada, N2L 3G1
Michael J. Worswick
Department of Mechanical Engineering,
University of Waterloo
, Waterloo, ON, Canada, N2L 3G1e-mail: worswick@lagavulin.uwaterloo.ca
J. Eng. Mater. Technol. Jan 2007, 129(1): 36-47 (12 pages)
Published Online: August 9, 2006
Article history
Received:
September 17, 2005
Revised:
August 9, 2006
Citation
Manoj Simha, C. H., Gholipour, J., Bardelcik, A., and Worswick, M. J. (August 9, 2006). "Prediction of Necking in Tubular Hydroforming Using an Extended Stress-Based Forming Limit Curve." ASME. J. Eng. Mater. Technol. January 2007; 129(1): 36–47. https://doi.org/10.1115/1.2400269
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