Atypical tube hydroforming system is shown in Figure 1. Within this system, a host of factors must be taken into account, from starting tube geometry and material properties to the quality of the final part (such as thickness distribution and dimensional accuracy). Each of these components plays an important role in the success of the process, and each must be addressed during the process development stage. Thus, the application of tube hydroforming technology must take the following into account: 1. Tube material and formability 2. Friction and lubrication 3. Preforming and prebending 4. Equipment 5. Cycle times and production rates This article discusses these points, along with how computer-aided simulation can aid a hydroformer in the process.
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