A Generative CAPP System for Tube Hydro Forming

Abstract

Tube hydro forming (THF) is a relatively complex manufacturing process. The performance of the process depends on many factors such as part geometry and design, material and process and the boundary condition of forming. Studying the behaviour of the process is by Finite Element-Computer Aided Engineering process has now become very popular and therefore, X- and T-branch shaped tubes have been taken to study the forming behaviour under THF coupled thermal and updated forming formulation through explicit solver as DEFORM using Computer Aided Engineering procedure. The simulation results have been compared with the experimental results and it agrees well. It is noted that the developed branch height and the wall thickness distribution along different planes of X and T are in good agreement with the experimental results. Based on several parametric studies and the simulation result, a Generative Process Planning system for THF has been proposed and validated with examples. © 2012, The Institution of Engineers (India).