FEM analysis of tube pre-bending and hydroforming

FEM analysis was conducted on tube pre-bending and subsequent hydroforming for a given hydroforming tooling in order to make possible modifications and optimization for the process planning to successfully form a given tubular part. Process variables such as the friction coefficient, the tube material and the pre-bent tube radius have been analyzed within the available conditions. It was found that a lower friction coefficient can reduce thinning in the pre-bending process, that SS304 is more favorable to the forming of this part than SS409, and that a large pre-bending radius is beneficial to both pre-bending and subsequent hydroforming.