In this article, a test method to determine the tube material properties and two methods to calculate the final hydraulic forming pressure of corrugated tubes are presented, based on plastic incremental theory. Numerical simulation and hydroforming experiment are carried out to demonstrate the reasonability of these methods. Simulation results show that tube force state during corrugated tube hydroforming is similar to that during tube local free hydraulic bulge. By comparison of final forming pressure respectively obtained from calculation, and hydroforming experiment, all of these methods are proved reasonable. Numerical simulation results also indicate that the two calculation methods still retain accuracy under different transition fillet radius, although transition fillets are ignored in calculation of final hydraulic forming pressure calculation.

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