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An important aspect of tube diameter selection is its suitability for both the hydroforming process and the tube making process. Validation is therefore carried out to check the tube diameter selection against both criteria. The tube diameter should be sized based on the minimum section perimeter for the component plus an allowance for a minimum sectional expansion, in the region of 2-5%. This ensures that all sections have some stretch and that the tube can be inserted into the die without pinching. Minimum section elongations less than 0% should be avoided. When the tube diameter is known it is also important to calculate the maximum sectional elongation and compare this to the total elongation property of the selected material. If the maximum sectional elongation is close to or exceeds this property it is advisable to either increase the tube diameter or revise the design to reduce the maximum section perimeter. | |
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