Enhancing hydroformability of nonaxisymmetric part with variable cross section

Methodology to enhance hydroformability of nonaxisymmetric thin-wall tubular component with variable cross sections was investigated in this study. In order to solve punch leakage problem occurred at nonaxisymmetric thin tube, the leak-resistive punch was suggested. Attaching lead at contact region of tube and punch was implemented to prevent leakage occurred due to uneven pressure distribution between punch and tube. And lead patch has also been attached at locally strain-concentrated tube surface to retard strain-concentrated necking. To validate the proposed enhancing methodology, nonaxisymmetric thin-wall tubular model part with variable cross sections has been hydroformed. The successful fabrication of model part that had previously failed during conventional hydroforming processing confirms the feasibility of proposed methodology.