A formability analysis for the tube-hydroforming process was investigated in the present study. The relationship between hydraulic pressure, outer corner radius of the deformed tube, the tube thickness and the tube yield stress was established based on a proposed theoretical model. Another theoretical model was also developed to calculate the die force generated in the tube-hydroforming process under frictionless condition. In order to validate the theoretical models developed, the two-dimensional finite element simulations were performed as well. The values predicted according to the proposed theoretical models are found to agree very well with those obtained from the finite element simulation results.
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