Application of the Numerical Model to Design the Geometry of a Unit Tool in the Innovative RTH Hydroforming Technology

The article presents a newly patented rapid tube hydroforming (RTH) manufacturing method, perfectly suited to single-piece production. The RTH technology significantly complements the scope of hydroforming processes. Due to the unusual granular material of the die tool, in particular moulding sand or mass, the process design requires the use of numerical modelling calculations. This is related to the complexity and the synergistic effect of process parameters on the final shape of the product. The work presents the results of numerical modelling studies of the process, including the behaviour of the die material and the material of the hydroformed profile. The numerical calculations were performed for a wide range of parameters, and can be used in various applications. The significant properties of moulding material used for the RTH tests were determined and one was chosen to build the die in RTH experiments. The results of the numerical modelling were compared with the results of the experiments, which proved their high compatibility. The final conclusions of the analyses indicate that the RTH technology has many possibilities that are worth further development and research.