Reshaping End-of-Life components by sheet hydroforming: An experimental and numerical analysis

In this study, a numerical/experimental analysis is proposed to investigate the possibility of reshaping sheet metal-based End-of-Life (EoL) components using Hydroforming (SHF). Returned EoL are challenging be reformed, they usually characterised by high heterogeneity as there localised thinning areas (caused original forming processes), and overall formability reduced with respect flat material. The route was replicated: deep drawing process adopted impart square feature; subsequently, SHF performed. capability remove drawn feature analysed varying Blank-holder force, oil pressure profile location previous feature. A 3D finite element model entire manufacturing used analyse strain paths process. change in when considering component previously subjected discussed comparison an undeformed blank. This study for first time provides insight on mechanics well attempts at quantifying quality reshaped components. Results revealed that can successfully purposes it performed under two aspects: removing existing imparting brand-new shape thickness/strain path analyses (avoiding fracture excessive thinning). Nevertheless, developed more than conventional new design rules, identified present paper, need followed.