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A new Hydro forming Die Design for Improvement of Die Corner Filling of Stepped Tubes

Abstract- Tubular components, such as stepped tubes, conical tubes and box-shape tubes, are mainly produced by tube hydroforming process. Obtaining a sharp corner is the main goal in some of these components. In this paper, corner filling in stepped tubes is studied using a new multistage hydroforming die. The proposed die was simulated and filling of the die cavity was investigated. The finite element software, ABAQUS 6.4, has been used for simulation. In order to verify the simulation results, the new die of stepped tube was manufactured and then experiments have been performed on it. The results of the experiments verified the simulation results. It was shown that by using the new die, parts with sharp corners could be produced. The simplicity of the die and the low internal pressure are among the advantages of this die.Thickness distribution was also examined by FE simulation and via experiments and it is shown that a better distribution could be obtained by the proposed die set. Keywords: Metal Forming, Tube Hydroforming, Stepped Tube, Finite Element Method.