Influence of the key process parameters in complex tube hydroforming

Abstract

Manufacturing pipe fittings with complex shapes by hydroforming has many advantages compared to casting and welding technology. That is, tube hydroforming achieves higher product quality and high productivity. However, the challenge with shaping complex pipe parts with this technology is identifying and controlling process parameters. In this study, the numerical simulation method is used, with the object of hydroforming being the pipe with two branches; the material is CDA110, and the workpiece diameter is 22mm. Research results determined the influence of critical parameters such as forming fluid pressure and displacement of the axial punches on part forming. The liquid pressure range that successfully includes the piece was from 74Mpa to 86Mpa, and the corresponding displacement of the axial punches was 20 to 24mm. This study has a meaningful reference for manufacturers. The research results make it possible to determine the influence of essential process parameters and choose an appropriate parameter range for successful tube hydroforming.