Hydroforming Process Using Numerical Study Based on a FEM:

Smoothed Particle Hydrodynamic Coupling Method

Hydroforming is employed in the manufacture of hollow monolithic products to reduce the number of joints. This method can reduce the weight and enhance the quality of fluid transfer parts in hydraulic system. Hydroforming is a process in which parts are formed into the shape of a mold using fluid pressure. An important issue in this process is adopting a loading path or, according to the knowledge of the process behavior based on the used systems and materials, the method of obtaining the appropriate loading path should be known. In the present research, a drop hammer was used to implement the dynamic loading path in the tests. This hammer lowers the number of systems to use and reduces the testing time. Accordingly, a single energy source was used simultaneously to provide axial feeding and internal pressure. To this end, designing a mold suitable for the dynamic loading path was necessary. This study investigates tubes’ deformation based on the applied impact and the amount of fluid in the mold. Moreover, axial feeding was provided with the help of different punches on the sides of the tube. Hence, the kinetic energy, amount of fluid, sealing, lubrication, and the material and thickness of the tube must be proportional for the correct forming of the tube. The hydrodynamic loading path can be studied using simulation. Thus, ABAQUS software was employed to observe the changes resulting from the process. From the smoothed-particle hydrodynamics perspective, it is a meshless method based on interpolation that uses a particle system to examine the system state and predict fields such as displacement, stress, and pressure. Moreover, several simulation results were examined for results accuracy to ensure convergence of the solution. The other observations of this research is that selecting side punches that have been to be proportional to the kinetic energy and the amount of fluid. it can be effective in knowing the better loading path