Finite-element analysis of bulge forming applying pressure and in-plane compressive load

Abstract Bulge tests for the determination of material characteristics are very common in engineering analysis. Apart from test purposes, the bulging technique is utilized for the forming of metal sheet-plate or tubes to various useful shapes. Both theoretical and experimental analysis of this forming technique have been done by several authors for different initial blank forms. Finite-element analysis of bulge forming has been carried out by a few authors. In these analyses, the bulging of diaphragms were simulated with edges clamped and hydraulic pressure applied as forming load. Finite-element analysis of the process incorporating the contact phenomenon between the die and sheet-plate has not been reported in the literature. The application of in-plane compressive load on the sheet-plate has also not been reported in any analysis. This paper attempts to study the effect of combined pressure and in-plane compressive load on the sheet-plate by the finite-element method. The contact condition between the die and the sheet-plate is also taken into consideration in the analysis. Further, the analysis is undertaken also for the pressure-only loading case and the results are compared. It is seen from the analyses that the bulge height obtained in the combined loading situation is much higher than that in the pressure-only loading situation. The bulge from the former has a more straight part and thinned less throughout. It also developed less stress and strain compared to the bulge formed in the pressure-only loading situation.

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