Finite Element Analysis and Experimental Study of Manufacturing Thin-Walled Five-Branched AISI 304 Stainless Steel Tubes with Different Diameters Using a Hydroforming Process
This study aims to investigate the feasibility of hydroforming (HF) technology coupled with response surface optimization for producing high-quality five-branched AISI 304 stainless steel tubes with different diameters, addressing the shortcomings of traditional manufacturing processes. Conventional...
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MDPI AG
2023-12-01
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| Online Access: | https://www.mdpi.com/1996-1944/17/1/104 |
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| author | Ali Abd El-Aty Yong Xu Wenlong Xie Liang-Liang Xia Yong Hou Shihong Zhang Mohamed M. Z. Ahmed Bandar Alzahrani Alamry Ali Xinyue Huang Arafa S. Sobh |
| author_facet | Ali Abd El-Aty Yong Xu Wenlong Xie Liang-Liang Xia Yong Hou Shihong Zhang Mohamed M. Z. Ahmed Bandar Alzahrani Alamry Ali Xinyue Huang Arafa S. Sobh |
| author_sort | Ali Abd El-Aty |
| collection | DOAJ |
| description | This study aims to investigate the feasibility of hydroforming (HF) technology coupled with response surface optimization for producing high-quality five-branched AISI 304 stainless steel tubes with different diameters, addressing the shortcomings of traditional manufacturing processes. Conventional techniques often result in issues with multiple consumables, low precision, and subpar performance. The research focuses on finding optimal forming parameters for a more effective process. Initial attempts at a five-branched tube proved unfeasible. Instead, a multi-step forming approach was adopted, starting with the formation of the upper branch tube followed by the two reducing lower branch tubes, a strategy termed “first three, then five”. This method, enhanced by a subsequent solid solution treatment, yielded promising results: the combined height of the upper and lower branches was 141.1 mm, with a maximum thinning rate of 26.67%, reduced to 25.33% after trimming. These outcomes met the product usage requirements. Additionally, the study involved designing and developing dies for manufacturing five-branched tubes with different diameters using servo HF equipment. The effectiveness of the multi-step forming process and parameter combinations was confirmed through experimental validation, aligning closely with the FE simulation results. The maximum thinning rate observed in the experiments was 27.60%, indicating that FE simulation and response surface methodology can effectively guide the production of high-quality parts with superior performance. |
| first_indexed | 2024-03-08T15:03:24Z |
| format | Article |
| id | doaj.art-7057ccf8b9bf432aae13de19e589b1f1 |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-08T15:03:24Z |
| publishDate | 2023-12-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Materials |
| spelling | doaj.art-7057ccf8b9bf432aae13de19e589b1f12024-01-10T15:02:36ZengMDPI AGMaterials1996-19442023-12-0117110410.3390/ma17010104Finite Element Analysis and Experimental Study of Manufacturing Thin-Walled Five-Branched AISI 304 Stainless Steel Tubes with Different Diameters Using a Hydroforming ProcessAli Abd El-Aty0Yong Xu1Wenlong Xie2Liang-Liang Xia3Yong Hou4Shihong Zhang5Mohamed M. Z. Ahmed6Bandar Alzahrani7Alamry Ali8Xinyue Huang9Arafa S. Sobh10Department of Mechanical Engineering, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al Kharj 11942, Saudi ArabiaShi-Changxu Innovation Center for Advanced Materials, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, ChinaShi-Changxu Innovation Center for Advanced Materials, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, ChinaSchool of Transportation, Ludong University, Yantai 264025, ChinaDepartment of Materials Science and Engineering & RIAM, Seoul National University, 1-Gwanak-ro, Gwanak-gu, Seoul 08826, Republic of KoreaShi-Changxu Innovation Center for Advanced Materials, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, ChinaDepartment of Mechanical Engineering, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al Kharj 11942, Saudi ArabiaDepartment of Mechanical Engineering, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al Kharj 11942, Saudi ArabiaDepartment of Mechanical Engineering, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al Kharj 11942, Saudi ArabiaShenyang Duoyuan Mechanical & Electrical Equipment Co., Ltd., Shenyang 110000, ChinaMechanical Engineering Department, Faculty of Engineering, Helwan University, Cairo 11795, EgyptThis study aims to investigate the feasibility of hydroforming (HF) technology coupled with response surface optimization for producing high-quality five-branched AISI 304 stainless steel tubes with different diameters, addressing the shortcomings of traditional manufacturing processes. Conventional techniques often result in issues with multiple consumables, low precision, and subpar performance. The research focuses on finding optimal forming parameters for a more effective process. Initial attempts at a five-branched tube proved unfeasible. Instead, a multi-step forming approach was adopted, starting with the formation of the upper branch tube followed by the two reducing lower branch tubes, a strategy termed “first three, then five”. This method, enhanced by a subsequent solid solution treatment, yielded promising results: the combined height of the upper and lower branches was 141.1 mm, with a maximum thinning rate of 26.67%, reduced to 25.33% after trimming. These outcomes met the product usage requirements. Additionally, the study involved designing and developing dies for manufacturing five-branched tubes with different diameters using servo HF equipment. The effectiveness of the multi-step forming process and parameter combinations was confirmed through experimental validation, aligning closely with the FE simulation results. The maximum thinning rate observed in the experiments was 27.60%, indicating that FE simulation and response surface methodology can effectively guide the production of high-quality parts with superior performance.https://www.mdpi.com/1996-1944/17/1/104five-branched tube with different diametersmulti-step hydroformingfinite element simulationresponse surface optimizationAISI 304 stainless steel |
| spellingShingle | Ali Abd El-Aty Yong Xu Wenlong Xie Liang-Liang Xia Yong Hou Shihong Zhang Mohamed M. Z. Ahmed Bandar Alzahrani Alamry Ali Xinyue Huang Arafa S. Sobh Finite Element Analysis and Experimental Study of Manufacturing Thin-Walled Five-Branched AISI 304 Stainless Steel Tubes with Different Diameters Using a Hydroforming Process Materials five-branched tube with different diameters multi-step hydroforming finite element simulation response surface optimization AISI 304 stainless steel |
| title | Finite Element Analysis and Experimental Study of Manufacturing Thin-Walled Five-Branched AISI 304 Stainless Steel Tubes with Different Diameters Using a Hydroforming Process |
| title_full | Finite Element Analysis and Experimental Study of Manufacturing Thin-Walled Five-Branched AISI 304 Stainless Steel Tubes with Different Diameters Using a Hydroforming Process |
| title_fullStr | Finite Element Analysis and Experimental Study of Manufacturing Thin-Walled Five-Branched AISI 304 Stainless Steel Tubes with Different Diameters Using a Hydroforming Process |
| title_full_unstemmed | Finite Element Analysis and Experimental Study of Manufacturing Thin-Walled Five-Branched AISI 304 Stainless Steel Tubes with Different Diameters Using a Hydroforming Process |
| title_short | Finite Element Analysis and Experimental Study of Manufacturing Thin-Walled Five-Branched AISI 304 Stainless Steel Tubes with Different Diameters Using a Hydroforming Process |
| title_sort | finite element analysis and experimental study of manufacturing thin walled five branched aisi 304 stainless steel tubes with different diameters using a hydroforming process |
| topic | five-branched tube with different diameters multi-step hydroforming finite element simulation response surface optimization AISI 304 stainless steel |
| url | https://www.mdpi.com/1996-1944/17/1/104 |
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