The Influence of the Protrusion Inclination Angle on the Formability of Hollow Joint in the Tube Hydroforming Process

Hollow joints formed through the tube hydroforming process offer superior advantages over traditional forming methods such as casting, welding, sheet metal bending, and cutting. The protrusion inclination angle of these hollow joints is a critical geometric parameter that directly influences their formability, including material deformation mechanics, wall thickness distribution, structural integrity, and more during the THF process. Optimizing this angle, along with other process parameters like internal fluid pressure load, axial feed, and counter pressure, can lead to significant improvements in the quality and complexity of the formed hollow joints. This paper focuses on studying the impact of three protrusion inclination angles—45 degrees, 60 degrees, and 90 degrees—on the formability of hollow joints HJ45, HJ60, and HJ90, based on numerical simulations using ABAQUS/CAE software. Output criteria used to analyze and compare the formability of the joints include forming stress distribution (S), plastic strain components (PE), material flow, wall thickness distribution (STH), and protrusion height. The research results can be utilized to enhance the design capabilities of various protrusions in hollow joints, as well as improve the efficiency of the tube hydroforming process in manufacturing products for applications in the automotive and aerospace industries.