ABSTRACT
Hydroforming of tubular components has been known by many other names such as bulge forming of tubes, hydrobulging, internal high-pressure forming and liquid forming of tubular components. T-branches/pieces, different types of tube items and water fittings, aircraft components, and automotive/vehicle parts are some of the components that are manufactured by tube hydroforming. The straight tube was first cut to a length of 4,870 mm after which it was rotary-draw bent at ten different zones. The bent tube was then placed in a hydroforming tool. An internal pressure of 30–35 bar was built up. The chapter deals with the fundamentals of tube hydroforming, analytical models, and finite-element simulations for free forming, some sheet and tube material related issues, the procedure used in the design, manufacturing engineering, and prototyping of industrial, particularly automotive, components and how holes can be made in the component in the hydroforming process. Finite-element simulation can be used to model hydropiercing.
