The Use of Internal Mechanical Insert to Prevent Wrinkling Defects in T-joint Hydroforming Process

In this study, the use of internal mechanical insert to prevent wrinkling defects in the process of T-shape tube hydroforming and expanding the window of the hydroforming process is presented. The study was performed both experimentally and by finite element simulation. In wrinkling limit testing, the use of internal mechanical insert for different modes prevented 100% of wrinkling and the T-joint was formed flawless, so that the wrinkles with high lengths such as 69.5 and 67.1 mm were prevented. Also, in the case of an internal pressure of 13 MPa and displacement of 33 mm, despite the high amount of axial displacement and the low internal pressure, the internal mechanical insert caused a reduction of 85.06% of the wrinkling length and the wrinkling length reduced from 74.3 to 11.1 mm. To study the conditions of the hydroforming process for both cases of with and without internal mechanical insert, the simulation of finite element was used. Experimental tests were also carried out to verify the validity of simulation results. By comparing the results of the experimental study and the simulations, an appropriate match was found between them. The results showed that the use of internal mechanical insert prevents wrinkling in the piece. Therefore, it can be used to produce a piece without defects and develop the window of the hydroforming process.