ẢNH HƯỞNG CỦA BÁN KÍNH CHUYỂN TIẾP KHUÔN ĐẾN QUÁ TRÌNH DẬP THỦY TĨNH PHÔI ỐNG PHÂN NHÁNH DẠNG CHỮ U

Abstract

Hydroforming (HF) is an advanced metal forming technology used to manufacture hollow components with complex geometries, in which the die shape-especially the transition radius-significantly influences material flow and forming quality. Although many studies have examined internal pressure and axial feeding, the effect of the transition radius on the hydroforming of branched tubes has not been clearly clarified.

This study simulates the hydroforming of a U-shaped branched tube made of CDA110 copper using Abaqus/CAE with three transition radius values: Rc = 4 mm, 6 mm, and
8 mm. As Rc increases from 4 mm to 8 mm, the bulge height increases by 12.4%, while the maximum wall thinning decreases by 4.6%. The PEEQ analysis indicates that a larger radius provides a more stable stress distribution and reduces stress concentration.

The results show that Rc = 8 mm is the optimal choice under the investigated conditions, ensuring better die filling and reducing the risk of failure. These findings provide valuable quantitative data for die design and process optimization in tube hydroforming, serving as a foundation for future studies and experimental validation.