Optimization of extruded preform dimensions for a T-shape hydroforming part based on response surface and finite element method

Tube hydroforming has been widely applied to produce seamless joints in oil and gas industry. The finite element analysis is used as an effective tool for optimization of hydroforming process. In this paper, a T-shape tube hydroforming process is simulated using the finite element method. The simulation was verified by experiments performed on T-shape tube hydroforming. The internal pressure, material model and other important simulation parameters was obtained from experiments. By using design of experiment methodology number of experiments with different thickness and length setting of initial tube were suggested. In order to avoid costly experiments, the finite element simulation was used. At last response surface methodology (RSM) were adopted to plot the results of the analysis. Since protrusion height, thickness reduction at protrusion region and thickness increase in central region of the product were important design parameters to control, the initial tube thickness and length was so optimized that the best possible product was achieved. Finally, a model using optimized initial tube was analyzed. The predicted amount of parameters was compared to those achieved from the analysis.The comparison showed a good agreement between the predicted and analyzed results.

Keywords:

Finite Element Method , Response Surface Methodology , Optimization , Tube hydroforming