The present paper aims to introduce a new finite element approach in numerical modeling of the impact tube hydroforming process. For this purpose, the coupled Eulerian-Lagrangian method is used to replicate the formation of the water flow, resulting from an impact, leading to the fabrication of flawless T-shaped copper tubes. One major advantage of such coupled Fluid-Structure Interaction (FSI) modeling is that it eliminates the need for measuring the parameters associated with the process including the internal pressure, and works with the minimum number of inputs such as the impact velocity. Moreover, ductile damage analysis has been performed in FE studies to further investigate the damage evolution in specimens. Experimental tests are also carried out to examine the viability of performing the impact tube hydroforming process in low velocities and also to validate the authenticity of the presented numerical method. Results corroborate the accuracy of the presented numerical approach in predicting the process parameters, the final shape, and the onset and evolution of rupture in fabricated tubes. The feasibility of this approach shows promise in wide application for finite element modeling of the hydroforming process.

本文旨在介绍冲击管液压成形过程数值模拟中的一种新的有限元方法。为此，使用耦合欧拉-拉格朗日方法来复制撞击产生的水流的形成，从而制造出完美的 T 形铜管。这种耦合流固耦合 (FSI) 建模的一大优点是，它无需测量与过程相关的参数（包括内部压力），并且可以使用最少数量的输入（例如冲击速度）。此外，在有限元研究中进行了延性损伤分析，以进一步研究样本的损伤演变。还进行了实验测试，以检验低速下执行冲击管液压成形工艺的可行性，并验证所提出的数值方法的真实性。结果证实了所提出的数值方法在预测制造管材的工艺参数、最终形状以及破裂的发生和演变方面的准确性。这种方法的可行性显示出在液压成形过程的有限元建模中广泛应用的前景。