Optimization Of Tube Hydroforming With Consideration Of Manufacturing Effects On Structural Performance

Tube bending and hydroforming processes depend on a multitude of design parameters including geometry of the part and tools, material properties and other process variables. Design by simulation has traditionally been a trial and error process, where the objective is to find a feasible and cost‐effective process to manufacture a defect‐free product by varying design parameters. This trial and error based design process can become extremely cumbersome as, the number of design variables and the complexity to vary them increases. Consequently, it is important to devise efficient methods that will minimize the tedious human intervention while maintaining a high level of interactivity and flexibility with regards to setting up of the optimization problem. In this study, such an interactive design tool is developed by coupling, nonlinear optimization methods with finite element analysis and morphing technology. The process setup is integrated through a unique software interface that provides complete flexibilit...