Tube hydroforming is a process that is used to manufacture rigid light-weight parts with complex cross sections by applying an internal hydraulic pressure, in combination with axial feeding or axial compressive loading. Tribological conditions in tube hydroforming (THF) are extremely important, since these conditions have a high influence in the final geometric characteristics and mechanical properties of the part formed by the THF process. In this study, the main objective is to develop a surface texture (which is composed of engraved micro channels) that will improve Tribological conditions at the die/tube interface during the expansion process in tube hydroforming. The characteristic material movement that occurs under a desired state of Tribological conditions can be used in order to design a die textured surface. Therefore, observation of this “trend” is of paramount importance for selecting the parameters that will yield a proper design (e.g. micro channel depth, channel geometry, engraved channel density). More specifically, instantaneous local material velocities, local surface enlargement and the state of stress can be observed via numerical simulations. This paper present strategies and preliminary analysis for determining micro channel die texturing to enhance tribological condition in THF.

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