Finite element simulation and experiment in tube hydroforming of unequal T shapes

Tube hydroforming of unequal T joints was simulated with finite element method. The code ABAQUS/EXPLICIT 6.3-1 was used and the effects of the coefficient of friction, strain hardening exponent and fillet radius on the parameters, protrusion height, thickness distribution and clamping and axial forces were studied. Curves for clamping and axial forces are very useful for estimation of the capacity for the press and hydraulic jacks. Also loading paths for different branch diameters have been determined. The amounts of calibration pressures and axial feedings required to produce an acceptable product in FEM were compared to experimental results and it was shown that there is a good agreement. Therefore, FEM can be used as a reliable tool in design of tube hydroforming processes and reduction of the number of costly trials.