Hydroforming for Small Hollow Protrusion in T- and X-Shaped Joints

Quang Vu Duc

doi:10.48084/etasr.14242

Authors

Quang Vu Duc Faculty of Mechanical Engineering, University of Economics - Technology for Industries, No. 456 Minh Khai, Vinh Tuy Ward, Hanoi City, Vietnam https://orcid.org/0000-0003-2158-583X

Volume: 15 | Issue: 6 | Pages: 29306-29311 | December 2025 | https://doi.org/10.48084/etasr.14242

Received: 22 August 2025 | Revised: 18 September 2025 and 24 September 2025 | Accepted: 27 September 2025 | Online: 8 December 2025

Corresponding author: Quang Vu Duc

Abstract

Traditional stamping and welding methods for creating small hollow protrusions in joints often lead to uneven deformation, material thinning, residual stress, and thermal stress. These issues compromise the material continuity, reduce the structural stiffness, and weaken the overall strength. This study applies the Tube Hydroforming (THF) process to improve the formation of small hollow protrusions in T- and X-shaped copper joints. Finite Element Method (FEM) simulations were carried out in Abaqus/CAE using a plastic material model and nonlinear contact conditions to evaluate five key factors: the effective range of forming fluid pressure, stress distribution within the component, Plastic Strain (PS) behavior, wall thickness variation, and protrusion height. The results revealed a common effective pressure range for both joint types. Compared to the T-joint, the X-joint exhibited less thinning at the protrusion apex and achieved a greater protrusion height. Overall, this study provides a reliable simulation framework for optimizing the THF process, reducing the experimental costs, and enhancing the quality of hollow joint production.

Keywords:

tube hydroforming, copper hollow joints, finite element analysis, process optimization

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