Experimental Investigation and Optimization of Bi-Layered Tube Hydroforming Process Parameters with Particle Swarm Optimization Algorithm

1Ph.D, Mech. Eng., Shahid Rajaee Teacher Training University, Tehran, Iran.
2Assis. Prof., Mech. Eng., Shahid Rajaee Teacher Training University, Tehran, Iran.
3Prof., Mech. Eng., Maleke Ashtar University of Technology, Tehran, Iran.
4Ph.D. Student, Mech. Eng., Tarbiat Modares University, Tehran, Iran.
Abstract
Determining of exact loading paths for bi-layered hydroforming are very neseccery to produce good products that confirmed design specifications. Unfortunately, theoretical formulas don’t exist to determine the process parameters. The process parameters were determined by trial-and-error and experiences of process planner. Therefore, a hybrid method of finite element and particle swarm optimization (PSO) was proposed for determining of the bi-layered hydroforming parameters. First, this process was simulated and verified by experimental data. Then, finite element and optimization algorithm were linked and used to determine of exact process parameters. Two constraints, thickness variations and maximum stress, were considered in the optimization process. Also, conformation of the geometrical dimension of the product with the design dimension was considered as a goal function. Pressure and feed loading paths were optimized in this research and both loading paths were assumed to be linear. Also, external and internal tubes materials are aluminium and copper, respectively. Python programming and ABAQUS software are used for hydroforming process simulation and linking the FE model and particle swarm optimization algorithm.