Modelling and Control of Hydroforming Processes for Flanges Forming

Abstract The modeling of hydroforming processes is studied from experiments and numerical modeling using advanced finite element methods. The paper demonstrates that simulation results fit well experiments. It also demonstrates that is possible to access control of process driving parameters, i.e. pressure in the die cavity or blank holder load in order to achieve a specified result in term of shape or thickness variation. The reliability and the accuracy of the proposed procedures are illustrated in the case of flange forming for different geometries and materials. It is demonstrated that the proposed method provides an accurate tool to help the process designer to assess the effect of process parameter on the final resulting sheet metal part.