Design and Optimization of TRB Blanks for Hydraulic Bulging Four-way Tubes

ZHANG Yu; JIANG Guobao; CHEN Zhenyi; HE Jianing; YUE Haojie

doi:10.3969/j.issn.1674-6457.2025.10.017

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Journal of Netshape Forming Engineering ›› 2025, Vol. 17 ›› Issue (10) : 175-182. DOI: 10.3969/j.issn.1674-6457.2025.10.017

Advanced Manufacturing Technology and Equipment

Design and Optimization of TRB Blanks for Hydraulic Bulging Four-way Tubes

ZHANG Yu^*, JIANG Guobao, CHEN Zhenyi, HE Jianing, YUE Haojie

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Abstract

To solve the uneven thickness of four-way tubes in hydraulic bulging, the work aims to design a continuous variable thickness tube blank. Firstly, according to the hydraulic bulging simulation of four-way tubes with the equal thickness tube blank, the change law of wall thickness was analyzed, and the design scheme of continuous variable thickness tube blank was proposed based on the simulation results. Secondly, the orthogonal test method was used to study the change law of tube blank thickness, and the key parameters of the thickness zone and transition zone of the continuous variable thickness tube blank were obtained. Finally, combined with the Universal Kriging Model and multi-objective particle swarm optimization algorithm, the optimal parameters were obtained by multi-objective optimization of the tube blank design. The wall thickness uniformity of the optimized continuous variable thickness tube blank was significantly improved. The finite element simulation results showed that the relative errors of the maximum relative thinning rate and the average thickness were less than 2%, and the uniform value of the wall thickness was reduced by 0.22 mm compared with the constant thickness tube blank. Compared with the traditional constant thickness tube blank, the continuous variable thickness tube blank can significantly improve the uniformity of the wall thickness of the four-way tube in hydraulic bulging and improve the product quality.

Key words

hydraulic bulging / continuous variable thickness tube / structure design / wall thickness uniformity / multi-objective optimization

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ZHANG Yu, JIANG Guobao, CHEN Zhenyi, HE Jianing, YUE Haojie. Design and Optimization of TRB Blanks for Hydraulic Bulging Four-way Tubes[J]. Journal of Netshape Forming Engineering. 2025, 17(10): 175-182 https://doi.org/10.3969/j.issn.1674-6457.2025.10.017

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