In-process feedback control of tube hydro-forming process

Abstract The present work will address the problem of designing an in-process control system for a tube hydro-forming process, controlling tool filling forming T-tube. is nontrivial as wrinkling and bursting develop rapidly and, in most cases, are irreversible—thus, must react fast without extensive overshoot. objective to filling, reproducing reference trajectory, where controller input defined correction pressure. was verified experimentally, using four different error scenarios. Initially, provoked, by manipulating signal, all three successfully eliminates both bursting. Finally, material changed going from aluminum grade 5049-0 6060-T6 also; this case, stabilizes process. strategy implementation developed numerical simulation (explicit finite element), reused directly experimental setup or scaling gain factors.