Finite Element Simulation and Optimization of the Hydroforming Process

The mechanical formulation for large plastic deformation of metals is recalled in view of tubes or sheet hydroforming simulation. The main features of the general purpose metal forming code FORGE3 are briefly summarized. Industrial tubes for hydroforming are generally thick enough so that a solid approach must be preferred to a thin shell analysis. The three-dimensional discretization into P1(+)-P1 tetrahedral elements with a mixed integral formulation allows us to model accurately the deformation of tubes in the thickness and is convenient for remeshing and adaptive remeshing. More recent developments that can be used for treating specific hydroforming problems are presented: computation of global fluid flow in function of the an imposed pressure, optimization of the process and damage analysis for predicting possible rupture of the work-piece. Several examples of three-dimensional computations are presented to show the versatility of simulation code.