Deformation behavior in the tube hydro-pressing of rectangular cross-section components

Deformation behavior in the tube hydro-pressing of rectangular cross-section components | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Deformation behavior in the tube hydro-pressing of rectangular cross-section components Yilin Luan, Yongpeng Zhuang, Gang Wang, Cong Han This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-4793137/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 30 May, 2025 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted 5 You are reading this latest preprint version Abstract Tube hydro-pressing is a new ultra-low pressure forming method proposed in recent years to address the problem of ultra-high forming pressure required by conventional hydroforming processes in forming high-strength materials or extreme size components. It changes the conventional hydroforming method of die closing before bulging to pressing after filling with liquid, which significantly reduces the forming pressure and makes it possible to form high-strength materials or extremely small round radii and large-sized components. Wrinkling is the main defect in the tube hydro-pressing process, therefore, the key to forming is to control wrinkling. Based on this, a critical wrinkling theoretical model is established for tube hydro-pressing based on plastic strain theory and energy conservation theorem. Experimental and numerical simulation studies were conducted on tube hydro-pressing, and the effects of the internal pressure and the compression ratio on thickness distribution and fillet filling were discussed. The accuracy of the theoretical model was verified by the experimental results, and the process window for tube hydro-pressing of a rectangular cross-section component was obtained. The results indicate that the critical internal pressure for tube hydro-pressing depends on the strength coefficient, hardening index, and compression ratio. The thickness of the sidewall is related to the internal pressure and compression ratio, and the greater the internal pressure, the poorer the uniformity of the sidewall thickness. The greater the compression ratio, the thicker the sidewall. The maximum thickening of the hydro-pressed part reached 13.4% when the compression ratio is 4%. In addition, the larger the compression ratio, the smaller the fillet radius. A rectangular tube with a corner radius of only 3.0mm was manufactured when the compression ratio is 4%. It can be concluded that the critical wrinkling pressure theoretical model is effective in predicting wrinkling, which provides theoretical guidance for the tube hydro-pressing method, accurately predicts wrinkling defects, and ensures the realization of large compression ratios. Tube hydro-pressing tube hydroforming critical internal pressure compression ratio Full Text Cite Share Download PDF Status: Published Journal Publication published 30 May, 2025 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted Editorial decision: Major Revisions Needed 21 Sep, 2024 Reviewers agreed at journal 28 Jul, 2024 Reviewers invited by journal 26 Jul, 2024 Editor assigned by journal 26 Jul, 2024 First submitted to journal 25 Jul, 2024 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-4793137","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":332181947,"identity":"cc48ff24-0f11-49cb-a6eb-0266a6a16a3f","order_by":0,"name":"Yilin Luan","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Yilin","middleName":"","lastName":"Luan","suffix":""},{"id":332181948,"identity":"8dcb5438-430e-4d27-9914-7b87ae470458","order_by":1,"name":"Yongpeng Zhuang","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Yongpeng","middleName":"","lastName":"Zhuang","suffix":""},{"id":332181949,"identity":"a4784d59-0065-4f57-9891-23c735d6669e","order_by":2,"name":"Gang Wang","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Gang","middleName":"","lastName":"Wang","suffix":""},{"id":332181950,"identity":"0f45e302-0393-489e-a6c3-2790f970c776","order_by":3,"name":"Cong Han","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAAyUlEQVRIiWNgGAWjYJACZiCWMwCRDGwkaDE2YGYmUUviBgZitfC39x5+XVBzJ307O/8Bhg9lhxn4Zzfg1yJx5lya9Yxjz3J3NjMzMM44d5hB4s4B/FoMJHLMjHnYDuduOMzMwMzbdhgokkCMln+H0w1AWv4SqcX4MdDwBLAWRmK0SJw5Y8bM23fYEOgwg4M959J5JG4Q0MLf3mP8mefbYXmD8wcfPvhRZi3HP4OAFiBgk4CxDgAxD0H1QMD8gRhVo2AUjIJRMIIBAJ4sPrizFa/IAAAAAElFTkSuQmCC","orcid":"","institution":"Harbin Institute of Technology","correspondingAuthor":true,"prefix":"","firstName":"Cong","middleName":"","lastName":"Han","suffix":""}],"badges":[],"createdAt":"2024-07-24 07:15:29","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-4793137/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-4793137/v1","draftVersion":[],"editorialEvents":[{"content":"https://doi.org/10.1007/s00170-025-15751-0","type":"published","date":"2025-05-30T15:57:26+00:00"}],"editorialNote":"","failedWorkflow":false,"files":[{"id":83782866,"identity":"18841155-d92c-47db-a96e-24984fb2f064","added_by":"auto","created_at":"2025-06-02 16:07:44","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":1433631,"visible":true,"origin":"","legend":"","description":"","filename":"manuscript.pdf","url":"https://assets-eu.researchsquare.com/files/rs-4793137/v1_covered_64cef8c1-a62f-4a13-a4a6-5a34f8185e6f.pdf"}],"financialInterests":"","formattedTitle":"Deformation behavior in the tube hydro-pressing of rectangular cross-section components","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":true,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false},"keywords":"Tube hydro-pressing, tube hydroforming, critical internal pressure, compression ratio","lastPublishedDoi":"10.21203/rs.3.rs-4793137/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-4793137/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eTube hydro-pressing is a new ultra-low pressure forming method proposed in recent years to address the problem of ultra-high forming pressure required by conventional hydroforming processes in forming high-strength materials or extreme size components. It changes the conventional hydroforming method of die closing before bulging to pressing after filling with liquid, which significantly reduces the forming pressure and makes it possible to form high-strength materials or extremely small round radii and large-sized components. Wrinkling is the main defect in the tube hydro-pressing process, therefore, the key to forming is to control wrinkling. Based on this, a critical wrinkling theoretical model is established for tube hydro-pressing based on plastic strain theory and energy conservation theorem. Experimental and numerical simulation studies were conducted on tube hydro-pressing, and the effects of the internal pressure and the compression ratio on thickness distribution and fillet filling were discussed. The accuracy of the theoretical model was verified by the experimental results, and the process window for tube hydro-pressing of a rectangular cross-section component was obtained. 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