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    Multipart Die Design for Bladeless Fan Housing Using the Tube Deforming Simulation
    (Springer Heidelberg, 2025) Karacan, Kivanc; Kacar, Ilyas; Yildirim, Sefa
    Tube deforming is a sheet metal manufacturing process that requires significant plastic deformations. It offers a potential to produce fast and burr-free tube deformation for bladeless fan housing. In this study, a multipart die and punch have been designed to facilitate this process. Finite element method-based simulations are performed to analyze the tube deformation of AA7075-T6. To enhance the accuracy of the simulation, two hardening models are combined. The combined rule involves a bilinear isotropic hardening model, characterized by its linear nature, and Chaboche's kinematic hardening model, which exibits a nonlinear nature. The raw parameters are determined using regression on the uniaxial tensile test data and low cycle fatigue data. The raw parameters are calibrated using inverse analysis and multi-objective genetic algorithm to specialize them in the tube deformation process where the deformation path is cyclic. The plasticity model is constituted of Hill48 yield criterion, the combined hardening rule, and associated flow rule. The novelty of this study is that the model parameters for the tube deformation process, which has a more complex deformation pattern, are acquired using only the data obtained from tensile and low cycle fatigue tests which are simpler to conduct. Additionally, linear and nonlinear models are combined for more accuracy and the calibrated parameters are established. The force-moment requirement and material flow path are also presented.