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Hamed Ziaei Poor,Hossain Ghorbani Menghari,Ricardo J. Alves De Sousa,Hassan Moosavi,Mahboubeh Parastarfeizabadi,Mahmoud Farzin,Hamed Sanei 한국정밀공학회 2014 International Journal of Precision Engineering and Vol. No.
Optimization of operating conditions is one of the most signicant issues concerning hydroforming the tubular components, includingstepped tubes, conical tubes, box shape tubes, and etc. Obtaining a sharp corner without any defects such as thinning and rupturingis one of the main goals in the production of these components. In order to manufacture tubes with filled corners, it is common toincrease the imposed pressure to the tubes. However, it may result in rupturing and thinning at the die corner radius, especially whenit is too small. In this paper, a new multistage die has been proposed for producing two stepped tubes. Numerical modeling has beenconducted using Abaqus/Explicit code. The results of simulation were afterwards checked against experiments in which it is shownthat a better thickness distribution could be obtained employing the proposed die set. There is no thinning in the final workpiece,particularly at the copper tube corners. Moreover, it could be possible to produce two stepped tubes with complete filled corners. Finally, comparing to other well-established methods, a lower pressure profile is required and a better thickness distribution can beachieved.