Investigation of Punch Shape and Loading Path Design in Hydro-Flanging Processes of Aluminum Alloy Tubes

Hydro-joining is composed of hydro-piercing, hole flanging and nut-inlaying processes. In this study, a new hydro-flanging process combining hydro-piercing proposed. An internal pressured fluid used as the supporting medium instead rigid die. Three kinds punch head shapes are designed to explore thickness distribution flanged tube leakage effects between in process. A finite element code DEFORM 3D simulate material deformation behavior investigate formability processes aluminum alloy tubes. The various forming parameters, such shapes, pressure, die diameter, etc., on hydro-flanged distributions discussed. Hydro-flanging experiments also carried out. radius make maximum pressure needed smaller than 70 MPa, so that general hydraulic power unit can be implement proposed experiments. compared with simulation results verify validity models shapes.