Feasibility of multi-layered tubular components forming by hydroforming and finite element simulation

Hydroforming is a type of unconventional metal forming process in which extremely high fluid pressure is used to deform the metal into a desired shape. Various types of complex industrial products can be made by hydroforming. In this paper, hydroforming of a multi-layer tube has been studied experimentally and by FE simulation. The simulation has been carried out by applying both internal pressure and in-plane compressive load as the main forming loads. The blank (double layered tube, outer layer is brass and inner layer is copper) is placed in a pre-shaped die block and due to the action of simultaneous load, it forms into a complex desired shape such as T or X branch. This process is suitable to produce seamless, lightweight, near net shaped industrial components. Simulation results have been verified by experiment on the basis of the deformation states of the formed components.