Two dimensional complex shape analyses during low pressure tube hydroforming

Hollow products are increasingly employed for automotive parts to reduce vehicle weight. Hydroforming technology is widely used for forming complicated or complex components from tube blanks. Complex shape can be easily formed with the help of high pressure. However high pressure equipments and high tonnage press are the resistance to product cost benefits. Whereas low pressure tube hydroforming can also achieve some of the complex shape with minimum pressure requirements and lower die closing force. This work represents the forming of two dimensional different complex shapes by using the low pressure tube hydroforming. The die filling conditions were critically studied. It is determined that for the complex shape with low pressure tube hydroforming slightly lesser perimeter length is required which allows for weight reduction. Stress and thickness distribution of the part during tube crushing were analysed.