Prediction of Rupture Using Ductile and MSFLD Damage in T-Shape Tube Hydro-Forming Process

Hydro-forming is a fabrication process that uses a fluid mediumto form a component by using high internalpressure. In tube hydro-forming, a tubular blank is placed between two dies, sealed and pressurized water injected, deforming the tube walls in the forming cavity of the dies. Several typical hydro-forming processes such as T- shapes, cross-shapes and Y- shapes exist. Successful hydro-forming depends on selection of proper tubular blank, sound preformed shape and internal pressure. In this paper, a 3D model of hydro-forming process of a T-shaped tube has been simulated by finite element method. Two damage models, coupled with von Mises plastic criterion, have been applied to predict where and when ductile and MSFLD rupture occur in the process. All studies presented in this paper have been carried out on aluminium alloy EN AW-7108 T6.