Identification of process parameters in CDA-110 copper T-shaped tube hydroforming

This study develops a systematic method to identify the optimal process parameters of a T-shaped tube hydroforming process. Three process parameters: (1) axial displacement, (2) pressure amplification, and (3) maximum inner pressure are examined to optimize two critical performance metrics: minimum wall thickness (STH) and branch height (Height). Finite element analyses were conducted in Abaqus/Explicit to characterize the input-output relationships. Multi-objective optimization based on the Pareto front approach is applied to identify optimal process parameters that trade-off between STH and Height. Numerical validation demonstrates the effectiveness of the presented method.