Optimisation of Tubular Hydroforming Processes for Wrinkling and Thinning Control

This paper is focused on the development and implementation of an innovative optimisation algorithm for the wrinkling and thinning control during the hydroforming of complex metallic parts. A straightforward numerical algorithm for simultaneous tracking and evaluation of the initiation of wrinkling/thinning defects was implemented, together with a numerical simulation program based on the Finite Element Method (FEM). After undesirable wrinkling/thinning patterns are identified during FEM simulation, the developed optimisation procedure (called Hybrid Differential Evolution Particle Swarm Optimisation - HDEPSO) is responsible to automatically correct the process input parameters, in order to achieve the successful forming of the desired part. In the end, the combined procedure (optimisation methodology + FEM) proved to be able to lead to a suitable numerical simulation and design tool for industrial hydroformed metallic tubular parts.