Classification and analysis of tube hydroforming processes with respect to adaptive FEM simulations

A classification of tube hydroforming (THF) processes based on sensitivity to loading parameters has been suggested. The characteristics of the classification have been analyzed in terms of failure mode, dominant loading parameters and their working windows. It is considered that the so-called pressure dominant THF process is the most difficult process for both simulation in FEM analysis and practical operation in real manufacturing situation. To effectively determine out the optimum loading path for pressure dominant THF process, adaptive FEM simulation strategies are mostly needed.