An investigation on tube hydroforming process considering the effect of frictional coefficient and corner radius

Abstract

ABSTRACTTube hydroforming (THF) technology is mostly used in automotive and aerospace industries because of its benefits like high precision, less weight and forming capability of complex shapes. Formability of the tube is the main factor for the consideration of the THF technologies in the industries. Thickness distribution in the bulged area is the key factor for the consideration of hydroformed parts. In the present paper, effects of coefficient of friction and corner radius of the die on bulge height and thickness distribution of the bulged area are studied using finite element method. Mechanical properties required to carry out the numerical simulations are evaluated by tensile, R-bar and pin-on-disc tests. Pin-on-disc experiments are carried out on the chosen material to find the wear and frictional coefficient with varying normal loads. Both numerical and analytical solutions are compared for the internal pressure required to bulge and burst the tube and observed to be in good agreement with each other. This study helps the researchers and industrialists for further understanding of the mechanics involved in the THF process in terms of die design and frictional effects.