In this work, a variable thickness tube blank geometry is proposed to be used in T-shaped tube hydroforming. The dimensions of the tube blank are optimized by the response surface method (RSM) linked with finite element simulation during T-shaped tube hydroforming. The influence of the wall thickness, angle and length of the tube blank are discussed on the thinning ratio and branch height. Multi-objective functions that relate objectives and design variables are formulated. Furthermore, the design variables having greatest impact on the objectives are obtained by sensitivity analysis. The optimal the geometric dimensions are determined within the given criterion by RSW and desirability approach. The optimized results have good agreement with the obtained results by finite element simulation and experiment.
By means of numerical simulation and experimental, the liquid filling forming process of an aluminum alloy double concave and convex curved sheet part was studied. The quality of forming parts, especially the thinning rate, is compared and studied during different hydroforming process. The results show that the thinning rate of the product is more than 25% regardless of the passive or active liquid filling drawing. However, the maximum thinning rate of the product is less than 20% when the hybrid hydroforming is carried out in a set of die with passive liquid filling in sequence, followed by pulsating reverse liquid filling. The method has reference significance for improving the forming quality of the parts with concave and convex surface of thin plate.
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