Bulge forming of tubular components.

The bulge forming process is a method for shaping tubular components using an internal hydrostatic pressure combined with a compressive axial load. Initial investigations involved carrying out an extensive literature survey to determine the components which could be formed and the effects of using lubricants and different tube materials. Die-blocks were designed to produce tee pieces, cross joints and off-set joints, and electronic on-line instrumentation was incorporated so that the forming pressures and loads could be accurately monitored. A series of tests were carried out in the forming of: (1) tee pieces, cross joints and off-set joints from copper tubes of two different wall thicknesses, (2) tee pieces using different types of plungers, (3) tee pieces using die-blocks coated with various lubricants, (4) tee pieces from aluminium, copper and steel tubes, (5) tee pieces using die-blocks with various branch radii. From the resulting components, formed with various combinations of internal pressure and compressive axial load, the limits for a successful forming operation were established. Further analysis of these components was then undertaken to evaluate the effects of the internal pressure and axial load on the bulge height and the wall thickness in the deformation zone. From these results, which have been illustrated graphically, the greatest effect on the resulting bulge can be seen to be the compressive axial load. Theoretical analyses are presented, which predict the wall thickness distribution around the bulge zone and also the axial loads required in the forming process. Comparison of these predictions with the experimental results shows fairly good agreement.