Design and analysis of a bulge test device

Abstract

The aim of this work is to present the methodological process to design a device capable of performing Bulge tests. This kind of device allows obtaining more information about the plastic behavior of a material than the one provided by a traditional tensile test. The engineering specifications of the device were evaluated through the QFD methodology. Then, a basic design of the device was performed based on available analytical models such as thick-walled pressure vessel theory, annular plate theory, and a basic plasticity model for the biaxial stress state. Later, a detailed design of the device was proposed, which was evaluated by means of a 3D model of finite elements and a linear-static analysis for the main components. Finally, a 2D axisymmetric model and a dynamic non-linear analysis were performed to validate the proposed design. The main novelty of the work consists of articulating the methodology of the mechanical design process and the conception, design, and validation of a Bulge device while solving the deficiencies found in the literature regarding the design and validation processes of this type of devices.