Tube Hydroforming Internal Pressure & Bulge Sizing Calculator
Calculate hydraulic expansion yield pressure (P_yield), corner calibration pressure (P_corner), axial punch feed force, and wall thinning % for automotive and aerospace tubular structures.
1. Input Parameters
2. Calculation Results
3. Geometric Visualizer
Tooling & Vector Prepress Engineering Notes
1. Corner Calibration Peak Pressure: In the final calibration stage, high pressure forces the tube wall against sharp die corner radii $R_c$: $P_{\text{corner}} = \frac{S_{\text{uts}} \cdot t_{\text{final}}}{R_c}$. Calibration pressures often reach $1,000 - 2,500\text{ bar}$.
2. Axial Force Material Feeding: Without axial feeding, free expansion thinning is $t_f = t_0 \sqrt{D_0 / D_{\text{max}}}$. Applying synchronized axial cylinder force pushes material into the expansion zone.
3. Split Die Parting Line DXF: Die parting lines must run along the profile neutral axis with tangential lock radii to prevent hydraulic flash pinch pinching during press clamp closure.