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<p>Tube hydroforming is an advanced metal forming process that uses highly pressurized fluid to deform metallic tubes into complex shapes. Tube hydroforming facilitates the manufacturing of lightweight, high-strength components with complex geometries. However, achieving uniform material distribution and preventing defects such as excessive thinning, buckling and premature bursting in T-shaped components remain significant challenges. The current research presents a comprehensive numerical and experimental investigation into the influence of various process parameters on the formability and quality of the hydroformed T-shaped component. For this research, stainless steel (AISI 304) tubes were used. An 50.8&#xa0;mm outer diameter and a thickness of 0.9&#xa0;mm tubes&#xa0;were hydroformed into the T-shaped component. The maximum possible bulge height through various parameters was studied. The pressure‒time and axial feed-time process parameters were optimized via a finite element (FE) modelling approach to achieve the desired, defect-free component. The experimental hydroforming system was used to manufacture the T-shaped component via the optimum set of parameters obtained through the FE simulations.</p>

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Modelling and Validation of Manufacturing T-Shaped Components via Tube Hydroforming Process

  • 期刊论文

  • 发表日期：

    2026年5月30日

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  • P. Harish,
  • K. Narasimhan

摘要

Tube hydroforming is an advanced metal forming process that uses highly pressurized fluid to deform metallic tubes into complex shapes. Tube hydroforming facilitates the manufacturing of lightweight, high-strength components with complex geometries. However, achieving uniform material distribution and preventing defects such as excessive thinning, buckling and premature bursting in T-shaped components remain significant challenges. The current research presents a comprehensive numerical and experimental investigation into the influence of various process parameters on the formability and quality of the hydroformed T-shaped component. For this research, stainless steel (AISI 304) tubes were used. An 50.8 mm outer diameter and a thickness of 0.9 mm tubes were hydroformed into the T-shaped component. The maximum possible bulge height through various parameters was studied. The pressure‒time and axial feed-time process parameters were optimized via a finite element (FE) modelling approach to achieve the desired, defect-free component. The experimental hydroforming system was used to manufacture the T-shaped component via the optimum set of parameters obtained through the FE simulations.