Hydroforming Processes for Tubular Parts
Optimisation by Means of Adaptive and Iterative FEM Simulation
In this article, some strategies are examined concerning the optimisation of hydro-mechanical
forming processes for tubular metal parts. The adopted approach consists in
using a finite-element model in which a feedback procedure is incorporated that optimises the
loading path (i.e., punch displacements and fluid pressure) with regard to the resulting
product. In the adaptive method, control parameters are adjusted during process simulation
for each subsequent time increment, depending on the outcome of the previous one. The
iterative method, on the other hand, is based on the minimisation of an objective function,
entailing repeated simulations of the whole process with modified control parameters. These
methods are used to assess the preferred settings for some typical test cases. Simulations
clearly illustrate the influence of the loading path on the obtained product. The adaptive
algorithm explores the wrinkling limit only, but is quick and flexible. The iterative algorithm
optimises the quality of the product in a more general sense, but needs extension beyond its
Wim H. SILLEKENS, Robert J. WERKHOVEN
Reçu le 24 août 2001.
Accepté le 7 novembre 2001.
Metal working, hydroforming, tube, process optimisation, finite-element method.