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Evaluating the flow stress of aerospace alloys for tube hydroforming process by free expansion testing

机译：通过自由膨胀测试评估用于管液压成形工艺的航空航天合金的流应力

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In order to obtain accurate tube hydroforming (THF) simulation results, one of the important inputs in the finite element model (FEM) of the process is the mechanical response of the material during THF. Generally, the mechanical response is defined by the stress-strain behavior that can be determined from tensile testing of the specimens extracted either from the sheet used for roll forming of the tubes or directly from the tubes. More recently, free expansion testing has been used to characterize the mechanical response of the material for hydroforming applications. The free expansion test can emulate process conditions similar to those found during THF, and as such, can be used to obtain reliable and accurate information on the mechanical response/properties of the tubular material. The aim of this research is to present an approach for evaluating the stress-strain behavior of different materials using a 3D deformation measurement system in conjunction with an analytical model. Here, to characterize the mechanical response of the materials, free expansion and tensile testing were used for austenitic stainless steel types 321 (SS 321) and 304L (SS 304L), INCONEL\uae alloy 718 (IN 718), and aluminum alloy 6061 in the annealed "0" temper condition (AA 6061-0). The mechanical response of each material, measured through free expansion testing of tubular forms, was compared to the respective stress-strain behavior determined from the uniaxial tensile test using ASTM E8 geometry specimens extracted from the tubes. For each material studied in this work, the two flow stress behaviors were distinct, indicating that the test method can have a noticeable effect on the mechanical response. Finite element analysis (FEA) of the free expansion of each material was also utilized to simulate the THF process with the flow stress curves obtained experimentally; the predicted expansion and burst pressure results were close to the experimental data indicating that the approach developed and described in this work has merit for characterizing the mechanical response of aerospace alloys for hydroforming applications. \ua9 2014 Her Majesty the Queen in Right of Canada.
机译：为了获得准确的管液压成型（THF）模拟结果，该过程的有限元模型（FEM）中的重要输入之一是材料在THF期间的机械响应。通常，机械响应由应力-应变行为定义，应力-应变行为可以通过对样品进行拉伸测试来确定，该样品可以从用于管材辊压成型的薄板中提取，也可以直接从管材中提取。最近，自由膨胀测试已用于表征用于液压成型应用的材料的机械响应。自由膨胀测试可以模拟类似于THF期间的工艺条件，因此可以用于获得有关管状材料机械响应/性能的可靠和准确的信息。这项研究的目的是提供一种使用3D变形测量系统结合分析模型评估不同材料的应力-应变行为的方法。在这里，为了表征材料的机械响应，对奥氏体321型不锈钢（SS 321）和304L（SS 304L），INCONEL \ uae合金718（IN 718）和铝合金6061进行了自由膨胀和拉伸测试。退火的“ 0”回火状态（AA 6061-0）。将通过管状形式的自由膨胀测试测得的每种材料的机械响应，与使用从试管中提取的ASTM E8几何样品从单轴拉伸测试确定的相应应力-应变行为进行了比较。对于这项工作中研究的每种材料，两种流动应力行为是不同的，这表明测试方法可以对机械响应产生显着影响。每种材料的自由膨胀的有限元分析（FEA）也用于通过实验获得的流动应力曲线模拟THF过程。预测的膨胀和爆破压力结果接近于实验数据，表明在这项工作中开发和描述的方法对于表征液压成形应用中的航空合金的机械响应具有优势。 \ ua9 2014年加拿大女王Queen下。

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