Determination of the optimal load path for tube hydroforming processes using a fuzzy load control algorithm and finite element analysis

Abstract

In the tube hydroforming process, the formability of a metallic tube is directly affected by the forming load path (i.e. axial feed and internal hydroforming pressure). Most tube hydroformed parts are produced by a multistage loading process. The forming limit strains induced during the actual forming operation are therefore path dependent. This paper discusses the optimisation of the forming load path of a typical tube hydroforming process using a fuzzy logic control algorithm, which avoids the failure of the tube due to excessive induced strain during the forming process. This control algorithm is used in conjunction with LS-DYNA FEA code for simulation of the forming process.