Internal state variable plasticity-damage modeling of the copper tee-shaped tube hydroforming process

This paper presents a parametric finite element analysis using a history-dependent internal state variable model for a hydroforming process. Experiments were performed for the internal state variable model correlation and for validating a 2-in. copper tee hydroforming process simulation. The material model constants were determined from uniaxial stress–strain responses obtained from tensile tests on the tube's material. In the finite element simulations, the mesh and boundary conditions were integrated with the geometry and process parameters currently used in industry. The study provides insights for the variation of different process parameters (velocity and pressure profiles, and bucking system characteristics) related to the finished product.