Experimental and numerical analysis on bilayer tube forming

J. M. Olevnik, C. P. Nikhare

Research output: Contribution to journalConference articlepeer-review


Moving deeper into the twenty-first century, lightweight construction has become a central principle in component design in industry-wide efforts towards increasing vehicle fuel economy to maintain adherence to tighter government environmental standards. To achieve new levels of weight reduction in components, simplistic materials are being replaced with compound materials and composites such as tailored blanks and multi-layered materials or 'hybrid' components when dissimilar materials are used together (metal and plastic polymer, for example). Usage of these new composite materials has been observed to yield lower component weights as well as the same or higher performance as conventional materials. To investigate this further, conical flaring of a hybrid, bilayer tube comprising an interior metal tube surrounded by an exterior polymer tube is considered. For experimentation, a steel inner tube was used with a PVC exterior tube. In testing, the formability of the steel tube was observed to have increased with the implementation of the exterior PVC layer in comparison to single layer tubes comprised of steel alone. Observation and analysis of this behavior pointed towards the contact stress of the two materials increasing the formability and delaying the failure. Beyond the scope of observing the flare, another property of the bilayer tube was that the addition of the PVC layer reduced the collapse of the steel tube adjacent to the flared region, which remained undeformed. The results of experimentation confirm that the hybrid component outperforms its conventional counterpart by exhibiting higher formability, lower stress in the flared region, and better overall structural integrity of the specimens after being flared.

Original languageEnglish (US)
Article number012130
JournalIOP Conference Series: Materials Science and Engineering
Issue number1
StatePublished - Sep 21 2018
Event37th International Deep Drawing Research Group Conference - Forming of High Performance Sheet Materials and Components, IDDRG 2018 - Waterloo, Canada
Duration: Jun 3 2018Jun 7 2018

All Science Journal Classification (ASJC) codes

  • General Materials Science
  • General Engineering


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