Multi-step hydroforming process and wall thickness optimization of 5A02 aluminum alloy five-way tube with different branch diameters

The different branch diameters of five-way tube affect the design loading internal pressure in hydroforming process, where large-diameter is broken more easily than small-diameter one due to same ultimate stress material one-step forming method. Therefore, first four-way and then multi-step (FFTF) method three-way (FTTF) were proposed fabricate 5A02 aluminum alloy with two kinds avoid burst tube. finite element simulation process shows that height lower serious wrinkles appear at FFTF By optimizing length punch, a big uniform wall thickness was obtained FTTF approach lengthening punch experiment increased formed reduced reduction rate Overall, findings mentioned above cannot only offer guide creating excellent quality, but also be taken as reference studies on multi-way future.