Finite element simulation of bulge forming of a cross-joint from a tubular blank

A finite element simulation of the manufacture of cross branches from straight tubes, using the bulge forming method, was performed to investigate the effects of varying process parameters. A finite element model was built and validated against experimental measurements. Two different types of loading were employed: internal pressure load only and combined internal pressure and axial loading. The effects of friction and tube thickness variation are examined, and deformations, stresses and tube thinning/thickening behaviour in the formed component are presented.