Effect of Anisotropic Yield Criterion on Simulation Accuracy in Hydroforming of Aluminum Alloy Extruded Tubes

doi:10.3901/JME.2025.04.167

Abstract

Abstract: The deformation behavior of extruded 6061-O aluminum alloy tube during the hydro-bulging process is studied by experiment and numerical simulation. By comparing experiments with simulation results predicted by commonly used anisotropic yield criteria Hill48, Barlat89, and Yld2000-2d, such as bulge height vs. pressure relationship, bulging profile and wall thickness vs. pressure relationship, the effect of yield criterion on the simulation accuracy of tube hydroforming and the reasons for its effect are clarified. The results indicate that the anisotropic yield criterion significantly affect the simulation accuracy of tube hydroforming. The reason for this lies in the ability of the yield criterion to accurately describe the yield behavior and plastic flow behavior under the corresponding loading conditions. In comparison to the Mises yield criterion, the Hill48 yield criterion has a lower overall prediction accuracy and is therefore deemed inadequate for simulating the hydroforming of aluminum alloy tubes. Despite being an improvement over Hill48, the Barrat89 yield criterion still exhibits a significant deviation. The Yld2000-2d yield criterion, however, offers the best agreement with experimental results and is therefore recommended for use in tube hydroforming simulation. The findings of this research provide valuable technical support for the application of yield criteria in tube hydroforming and contribute to the field’s knowledge base.

Key words: tube, hydroforming, yield criterion, anisotropy, numerical simulation

CLC Number:

TG301

ZHANG Kun, BAI Xueshan, SUN Jin, HU Xinyu, LIN Yanli, HE Zhubin. Effect of Anisotropic Yield Criterion on Simulation Accuracy in Hydroforming of Aluminum Alloy Extruded Tubes[J]. Journal of Mechanical Engineering, 2025, 61(4): 167-175.

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