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The purpose of this study is to improve the bulging and minimise the thinning ratio so that manufacturing processes will be improved in Industries. Tube hydroforming is an advanced manufacturing technology used for making intricate and complex tubular parts which required less cycle time. This research focusses on hydroforming process, formability and process parameters design for replacing the conventional tube bending, welding and cutting operations. The prediction of parameters is done by applying numerical and experimental approach. During experimentation the pressurised fluid is used to deform the tubes in a plastic deformation. In this study, two types of grade materials are used such as AISI304 and AISI409Lof 57.15 mm external diameter with 1.5 mm thickness in the form of ERW tubes to measure stain path, thinning and bulge height. However, it is observed that the internal pressure and L/D ratio are effective parameters in both numerical analysis and experimentation. In axial feed condition, it is observed that 7.7% thinning in weld region and 24.9% thinning in base metal region, whereas, in fixed feed condition, it is observed that 9.2% thinning in weld region and 26.2% thinning in base metal region for L/D = 1 and L/D = 3, respectively. The numerical analysis with experimental results shows a very good match.

Numerical and experimental predictions of formability parameters in tube hydroforming process