Numerical simulation and experimental study on hydroforming of variable diameter tube

Numerical simulation and experimental study on hydroforming of variable diameter tube | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Numerical simulation and experimental study on hydroforming of variable diameter tube Jian Li, Jiachun Yang, Jiachen Wang, Yi Sun, Jin Wang, Shiming Zu, and 3 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7306003/v1 This work is licensed under a CC BY 4.0 License Status: Under Review Version 1 posted 4 You are reading this latest preprint version Abstract The forming accuracy of finite element simulation mainly depends on the accuracy of constitutive model. In order to solve the problems of complex hydroforming processes and low success rate of sample trial production, the method of improving the accuracy of numerical simulation and the control accuracy of experimental equipment was proposed to carry out the trial production of sample hydraulic forming of variable diameter tube. In this paper, starting from the study of the circumferential mechanical properties of the tube, the circumferential mechanical properties of the original tube blank are obtained by using the experimental device of tube end flaring, which is used for the numerical simulation study of variable diameter tube hydroforming, so as to improve the numerical simulation accuracy of the internal high pressure forming process. Then, in order to improve the axial feed control accuracy of the original equipment, a reduced-diameter tube hydroforming system based on servo-electric cylinder is built, and the corresponding experimental research is carried out. At the same time, through the hydroforming experiment of variable diameter tube, the thickness distribution results obtained by numerical simulation are compared with the experimental results to verify the correctness of the numerical simulation method and the established finite element model. Finally, the loading path is optimized by combining experiment and simulation, and it is verified by experiment. The experimental results show that by improving the accuracy of numerical simulation and the control accuracy of experimental equipment, the success rate of the trial production of variable diameter tube samples can be effectively improved and the trial production period can be shortened. Hydroforming Circumferential mechanical properties Variable diameter tube Numerical simulation Trial production of samples Full Text Cite Share Download PDF Status: Under Review Version 1 posted Reviewers agreed at journal 01 Oct, 2025 Reviewers invited by journal 30 Sep, 2025 Editor assigned by journal 14 Aug, 2025 First submitted to journal 12 Aug, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-7306003","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":523160820,"identity":"adb80e39-5e47-43ba-a114-922182c3685a","order_by":0,"name":"Jian 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In order to solve the problems of complex hydroforming processes and low success rate of sample trial production, the method of improving the accuracy of numerical simulation and the control accuracy of experimental equipment was proposed to carry out the trial production of sample hydraulic forming of variable diameter tube. In this paper, starting from the study of the circumferential mechanical properties of the tube, the circumferential mechanical properties of the original tube blank are obtained by using the experimental device of tube end flaring, which is used for the numerical simulation study of variable diameter tube hydroforming, so as to improve the numerical simulation accuracy of the internal high pressure forming process. Then, in order to improve the axial feed control accuracy of the original equipment, a reduced-diameter tube hydroforming system based on servo-electric cylinder is built, and the corresponding experimental research is carried out. At the same time, through the hydroforming experiment of variable diameter tube, the thickness distribution results obtained by numerical simulation are compared with the experimental results to verify the correctness of the numerical simulation method and the established finite element model. Finally, the loading path is optimized by combining experiment and simulation, and it is verified by experiment. The experimental results show that by improving the accuracy of numerical simulation and the control accuracy of experimental equipment, the success rate of the trial production of variable diameter tube samples can be effectively improved and the trial production period can be shortened.\u003c/p\u003e","manuscriptTitle":"Numerical simulation and experimental study on hydroforming of variable diameter tube","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-10-14 11:11:02","doi":"10.21203/rs.3.rs-7306003/v1","editorialEvents":[{"type":"communityComments","content":0},{"type":"reviewerAgreed","content":"","date":"2025-10-01T04:42:30+00:00","index":0,"fulltext":""},{"type":"reviewersInvited","content":"","date":"2025-10-01T03:57:18+00:00","index":"","fulltext":""},{"type":"editorAssigned","content":"","date":"2025-08-14T09:00:06+00:00","index":"","fulltext":""},{"type":"submitted","content":"The International Journal of Advanced Manufacturing Technology","date":"2025-08-12T11:56:38+00:00","index":"","fulltext":""}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false}}],"origin":"","ownerIdentity":"3db76c28-5d50-4ce4-a10b-f203245a2d41","owner":[],"postedDate":"October 14th, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"under-review","subjectAreas":[],"tags":[],"updatedAt":"2025-10-14T11:11:03+00:00","versionOfRecord":[],"versionCreatedAt":"2025-10-14 11:11:02","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-7306003","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-7306003","identity":"rs-7306003","version":["v1"]},"buildId":"8U1c8b4HqxoKbykW_rLl7","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}