Low velocity impact tube hydroforming process: experiments and FSI modeling by considering ductile damage model

The present paper aims to introduce a new finite element approach in numerical modeling of the impact tube hydroforming process. For this purpose, the coupled Eulerian-Lagrangian method is used to replicate the formation of the water flow, resulting from an impact, leading to the fabrication of flawless T-shaped copper tubes. One major advantage of such coupled Fluid-Structure Interaction (FSI) modeling is that it eliminates the need for measuring the parameters associated with the process including the internal pressure, and works with the minimum number of inputs such as the impact velocity. Moreover, ductile damage analysis has been performed in FE studies to further investigate the damage evolution in specimens. Experimental tests are also carried out to examine the viability of performing the impact tube hydroforming process in low velocities and also to validate the authenticity of the presented numerical method. Results corroborate the accuracy of the presented numerical approach in predicting the process parameters, the final shape, and the onset and evolution of rupture in fabricated tubes. The feasibility of this approach shows promise in wide application for finite element modeling of the hydroforming process.