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<p>Three-way tube with single-side flanged features has been widely used in automobile and airplane fields. The susceptibility of lightweight alloys to crack at room temperature makes the preparation of aluminum alloy Three-way tubes a challenge. In this paper, the numerical model of electrohydraulic forming process was established and validated. The deformation process was analyzed. Three-way tubes of different design heights were prepared. The clearance and wall thickness were used to characterize the forming quality. The effect of discharge voltage on forming quality was explored. Results showed that the increase of discharge voltage could improve the shape accuracy of three-way tube. Spring-back was observed, but the maximum clearance in straight-wall area was controlled within 0.16&#xa0;mm. With the increase of discharge voltage, the thickness decreased. This process enables the preparation of three-way tubes of different design heights without cracking.</p>

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Simulation and experimental study of electrohydraulic forming of three-way tube

  • 期刊论文

  • 发表日期：

    2025年9月17日

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  • Da Cai,
  • Yinlong Song,
  • Hang Ou,
  • Hao Jiang,
  • Junjia Cui,
  • Guangyao Li

摘要

Three-way tube with single-side flanged features has been widely used in automobile and airplane fields. The susceptibility of lightweight alloys to crack at room temperature makes the preparation of aluminum alloy Three-way tubes a challenge. In this paper, the numerical model of electrohydraulic forming process was established and validated. The deformation process was analyzed. Three-way tubes of different design heights were prepared. The clearance and wall thickness were used to characterize the forming quality. The effect of discharge voltage on forming quality was explored. Results showed that the increase of discharge voltage could improve the shape accuracy of three-way tube. Spring-back was observed, but the maximum clearance in straight-wall area was controlled within 0.16 mm. With the increase of discharge voltage, the thickness decreased. This process enables the preparation of three-way tubes of different design heights without cracking.