Numerical Simulation and Optimization of a Tee Shaped Tube Hydroforming Process

We performed numerical simulations and multiobjective optimization of a hydroforming process for copper tees using the BCJ plasticity material model developed by Bammann et al., which accounts for material manufacturing and history effects. A finite element simulation of the hydroforming process was created using data from experiments and the industrial process. The process parameters and geometry factors were optimized using a multiobjective optimization methodology employing metamodeling and software developed at Mississippi State University’s Center for Advanced Vehicular Systems.