Abstract
Abstract This study is to propose a loading scheme combined with die crushing and axial feeding to manufacture a profiled tube with different end shapes. Carbon steel of SPFC590Y is used as the tube material. The flow stresses of SPFC590Y steel tube at room temperature are obtained by tensile tests. A finite element software DYNAFORM is adopted to simulate the plastic deformation of the profiled tube during hydroforming and crushing processes. The effects of forming schedules on the formability and thickness distributions of the products are discussed. Finally, a profiled die set and a rectangular punch head are designed and manufactured, and experiments of hydroforming and crushing processes of ERW steel tubes are conducted using a self-designed hydroforming machine. Experimental results of product shapes and thickness distributions are compared with the simulation results to verify the validity of the finite element modelling and the designed loading schedules.
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