Optimizing tube hydroforming using process simulation and experimental verification

Abstract

The success of a tube hydroforming (THF) process is highly dependent on the loading paths (axial feed versus pressure) used. Finite element (FE)-based simulation was used to determine optimum loading paths for hydroforming of structural parts with different tubular materials. Experimental and simulation results have demonstrated that FE-based loading paths can significantly reduce trial and error, enhance productivity and expand the THF capability in forming complex parts. The test results also demonstrated that the reliability of the FE-based loading paths is highly dependent on the accuracy of the material properties of the blank, interface friction, and how close the properties of the welding zone are to the base material of the tubular blank.

The multi-objective optimization of the loading paths for T-shape tube hydroforming using adaptive support vector regression

“…References [3][4][5][6][7][8][9] applied the adaptive simulation method, which is based on the ability to detect the onset and growth of defects during the process and promptly react to them, to obtain a set of feasible loading paths with a minimum number of simulation run or even with a single run. Strano et al [3] pointed out that when finite element (FE) simulation is used to reduce engineering effort and lead times, a reliable input data, namely the constitutive parameters of tubular material and lubrication conditions, for THF process simulation is needed.…”

The multi-objective robust optimization of the loading path in the T-shape tube hydroforming based on dual response surface model

“…Kadkhodayan and Moghadam [19,20] established a new method to optimize the loading parameters in the T-, X-, Y-shape THF process based on Taguchi method and the RS model. Aue-U-Lan et al [21] studied the self-feeding and the adaptive simulation techniques as the optimization strategies to optimize the loading parameters. Mirzaali et al [22,23] used the simulated annealing algorithm to find the loading parameters in the THF process.…”

Finite element modeling of tube hydroforming of polycrystalline aluminum alloy extrusions

“…Selection of load (internal pressure) and end condition (axial feed) will affect the formability of a metallic tube in the tube hydroforming process. The influence of these parameters was studied by Imaninejad et al (2004), Ray and MacDonald (2004), Aue-U- Lan et al (2004), Johnson et al (2004), Hsu (2003, and Fann and Hsiao (2003). Most recently, researchers studied failure phenomenon (wrinkling, bursting, necking, etc.)…”