Virtual process development in tube hydroforming

In order to successfully develop a new tube hydroforming (THF) process, a system approach is recommended. Problems and improvements in each area of the THF technology and their interactions should be considered. In the product and process design phases, in order to reduce the cost of physical prototyping, virtual prototyping, i.e. computer simulation using finite element analysis (FEA) plays a major role. Both input data and strategies used in FEA must be carefully selected, if an accurate and relatively fast response is required. The first part of this paper briefly reviews the technological areas, critical for obtaining reliable input FEA data, i.e. quality and material properties of incoming tubes and die–workpiece interface issues. The second part describes some of the FEA strategies developed and currently used at the ERC/NSM for effective process design.