This paper proposes a new method to design the optimal load curves for hydroforming T-shaped tubular parts. In order to assess the mathematical models, a combination of design of experiment and finite element simulation was used. The optimum set of loading variables was obtained by embedding the mathematical models for tube formability indicators into a simulated annealing algorithm. The adequacy of the optimum results was evaluated by genetic algorithm. Using this method, the effect of all loading paths was considered in hydroforming of T-shaped tubes. Eliminating of variables with lower effect could simplify the problem and help designers to study the effect of other parameters such as geometrical conditions and loading parameters. Applying the optimal load paths obtained with the proposed method caused an improvement in the thickness distribution in the part as well as a decrease in maximum pressure.
This paper addressed the modeling and optimization of loading path in T-shape hydroforming of tubes using Simulated Annealing (SA) algorithm. Analysis of variance shows that some of pre-selected parameters in loading paths have not significant effect on the deformed tube. Hence, some of optimized parameters found initially, are replaced with their own fixed optimum values in order to seek for the other parameters in more detail by the Simulated Annealing (SA) algorithm. According to the intensity of effectiveness on the deformation, six more important parameters are chosen and their minimum and maximum limitation values are determined. In this case, sixty four different tests for different loading paths are designed by Design of Experiment (DOE) and full factorial method. By using mathematical modeling all required loading parameters are obtained. Proposed models of formability embedded into Simulated Annealing algorithm and optimum value for loading parameters and optimal load paths are found. The obtained results show that more accurate loading path may be found for T-shape of tube hydroforming.
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