Adaptive simulations in T-shape tube hydroforming with different outlet diameters

A successful tube hydroforming process depends largely on the loading paths for controlling the relationship between the internal pressure, axial feeding and the counter punch. The objective of this article is to propose an adaptive control algorithm to determine appropriate loading paths in T-shaped protrusion hydroforming with different outlet diameters. The finite element analysis is used to simulate the flow pattern of the tube during tube hydroforming process. The analytical flow line net configuration of the tube is utilized to determine the speed ratio of the counter punch to the axial feeding at the protrusion stage. Appropriate loading paths for different outlet diameters are determined using the proposed adaptive control algorithm. Different pressurization profiles are used in the tube hydroforming experiments. Experimental results show that a sound product is obtained using the pressurization profile determined by the proposed adaptive simulation algorithm. From the comparisons of the product shape and flow line net configurations between the analytical and experimental values, the validity of the proposed control algorithms is verified.