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<p>To address issues such as severe wall thinning and cracking in automotive curved exhaust tube components during conventional hydraulic forming, a bulging-pressing compound-deforming process was adopted. Using 441 stainless steel as the material, preforming for optimization of material distribution to ensure wall thickness and forming accuracy, followed by final forming. An analysis is performed using ABAQUS to examine the effects of four process parameters on the forming quality: the section modulus, axial feed stroke, support internal pressure, and shaping internal pressure. Results indicate that with a preforming section modulus of 1, optimal forming occurs at final parameters of 4.5&#xa0;mm axial feed stroke, 11&#xa0;MPa support internal pressure, and 25&#xa0;MPa shaping internal pressure. Under these conditions, the maximum thinning rate was 12.51%, and the maximum gap between the tube and die was 0.365&#xa0;mm. The simulation results were in good agreement with the experimental data, validating the authenticity of the process and the reliability of the simulation outcomes.</p>

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Research on the bulging-pressing compound-deforming process for automotive curved exhaust tubes

  • 期刊论文

  • 发表日期：

    2026年7月23日

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  • Xinlong Zhang,
  • Tianbang Jiang,
  • Xueyan Liu,
  • Enshu Zhang,
  • Qihao Xu,
  • Chunmei Yang

摘要

To address issues such as severe wall thinning and cracking in automotive curved exhaust tube components during conventional hydraulic forming, a bulging-pressing compound-deforming process was adopted. Using 441 stainless steel as the material, preforming for optimization of material distribution to ensure wall thickness and forming accuracy, followed by final forming. An analysis is performed using ABAQUS to examine the effects of four process parameters on the forming quality: the section modulus, axial feed stroke, support internal pressure, and shaping internal pressure. Results indicate that with a preforming section modulus of 1, optimal forming occurs at final parameters of 4.5 mm axial feed stroke, 11 MPa support internal pressure, and 25 MPa shaping internal pressure. Under these conditions, the maximum thinning rate was 12.51%, and the maximum gap between the tube and die was 0.365 mm. The simulation results were in good agreement with the experimental data, validating the authenticity of the process and the reliability of the simulation outcomes.