The optimization of a hydroformed tube

The shaping by hydroforming process involves several complex phenomena and presents several types of nonlinearities (geometric, material,...). The development of a hydroforming operation requires a lot of testing to determine with precision the optimum loads of trips and get a room without defects. Advances in digital tools have enabled manufacturers to simulate and optimize their production facilities before launching the production in order to minimize the maximum rate of defective parts.

On the Friction Effect on the Characteristics of Hydroformed Tube in a Square Section Die: Analytical, Numerical and Experimental Approaches

A focus on the effect of friction condition on tube hydroforming during corner filling in a square section die is proposed. Three approaches have been developed: an analytical model from the literature has been programmed, finite element simulations have been conducted and experiments have been carried out. Effect of friction coefficient on the thickness distribution in the square section of the hydroformed tube is studied. Critical thinning is found to take place in the transition zone between the straight wall and the corner radius and this minimal thickness seems to be the more appropriate parameter for the evaluation of the friction coefficient.