Investigation of the effective parameters in tube hydroforming process by using experimental and finite element method for manufacturing of tee joint products

Hydroforming is a prominent manufacturing process in automotive, aerospace, and aircraft industries. This process has several advantages compared with other conventional production method, such as weight reduction, part consolidation, improved structural strength, better stiffness, welded assembly obviation, dimensional accuracy, low spring back, and increasing in design flexibility. In tube hydroforming (THF) process, product quality mainly depends on some parameters which determine the boundary conditions of forming process. In the present work, the effect of loading path, friction coefficient, strain-hardening exponent, and fillet radius of the die on height of protrusion in expansion zone and thickness distribution in three different cross-sections is perused. In order to investigate the effects of abovementioned parameters on product quality, finite element method (FEM) was used via ABAQUS/Explicit, as well as to perform the THF process experimentally, a tubular blank was placed between two dies, sealed and filled by injecting pressurized water into it and at last, the tubular blank was shaped into die cavity. The FEM results were then compared with experimental results and were found a good compatibility between them. Finally, according to the results, a useful pattern obtained to show the relevance between effective parameters and product quality. Carefully selected combined parameters can be considered as a key factor for successful THF as well as enhance the formability.