Finite element simulation of T-shape branch using Tube- hydroforming process

The capability of the Tube-hydroforming process (THP) to shape the ductile material tubes in a single stroke makes the process more advantageous over the conventional forming process. The dimensions of the shape control by the process variables like internal pressure, axial feed, temperature, etc. In this paper, a cylindrical C12200 (copper alloy) tube and T-shape die is modelled using CATIA V-5. Subsequently, the model is simulated using ANSYS V-16 under the appropriate boundary conditions. For model validation, the simulation results i.e. bulge height of tube and Von–Mises stress are compared with previous research work. The maximum percentage error is 16.89% in values of bulge height and 14.98% in values of Von-Mises stress. Further, the tube is heated up to recrystallization temperature and simulation analysis is performed with the same boundary conditions as before. It is observed that in the case of heated tube the values of bulge height and Von-Mises stress are more than the values obtained in the earlier case.