Virtual fuzzy in-process control of Y-shape tube hydroforming with different branch top shapes

In this study, a new counter punch shape was designed and applied to Y-shape hydroforming to obtain a Y-shape tube with uniform wall thickness. The new counter punch shape effect in Y-shape hydroforming using fuzzy control was investigated in finite element simulation. As a result, the wall thickness thinning in the branch top was restrained and the wall thickness thickening in the die shoulder of obtuse angle side was restrained. The results suggested that the wall thickness could be more uniform by using the new counter punch.