Abstract
The success of Tube HydroForming (THF) operations is largely dependent on the selection of the loading paths: internal pressure vs. time and axial feed vs. time. The Finite Element Method is often used to reduce the cost of prototyping. In this paper, the adaptive simulation concept is presented as an effective FEM approach, able to select a feasible THF loading path within a minimum number of simulation runs or even within a single run. The adaptive simulation technique is based on the ability to detect the onset and growth of defects (wrinkling, buckling, bursting) and to promptly readjust the loading paths. The detection and quantitative evaluation of wrinkles play a key role in the implementation of the adaptive simulation. Therefore, a new geometrical wrinkle indicator is introduced and evaluated with numerical and experimental evidence. The proposed wrinkle indicator is computationally inexpensive, suitable for many die shapes and sensitive to different kinds of wrinkles.
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