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Abstract
A new kinematically admissible velocity field is suggested for the upper-bound solution of three-dimensional hydroforming of regular polygonal boxes. In order to maintain the uniform wall thickness a back-up fluid pressure is controlled to vary with respect to the punch position during the hydroforming process. Thus the pressure vs punch stroke curves for various process conditions are determined from theoretical analysis. The effects of the work-hardening exponent, drawing ratio and friction are then analyzed and discussed. Control of the hydroforming pressure with respect to the punch stroke is shown to be very important for proper design of the process.
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