Evaluation of Hydroforming Parameters for Motorcycle Exhaust Pipe Production Using FEM Simulation

Subject Areas :

Mohammad Sajjad Mahdieh ^{1 *} , Farshad Nazari ² , Laith Jawad ³

1 - Department of Mechanical Engineering, Shahid Chamran University of Ahvaz, Ahvaz, Iran
2 - Mechanical Engineering Department, Shahid Chamran University of Ahvaz, Ahvaz, Iran
3 - Department of Mechanical Engineering, Shahid Chamran University of Ahvaz, Ahvaz, Iran

Received: 2025-02-08 Accepted : 2025-04-18 Published : 2025-05-09

Keywords: Metal Forming, Hydroforming Process, ABAQUS, Automotive Industry, FEM Simulation,

Abstract :

By utilizing the hydroforming technique, parts with enhanced fatigue strength can be produced without the need for welding seams. Additionally, in the automotive sector, the production of complex cylindrical components from metal pipes has gained attention, particularly for improving the strength-to-weight ratio and reducing vehicle fuel consumption. As a result, automobile manufacturers have increasingly focused on this method. Understanding the key factors influencing the successful execution of this process is essential for achieving high-quality products, optimal geometry, improved efficiency, and cost reduction. To examine material behavior during hydroforming and to avoid significant material loss, simulation procedures are crucial. This study investigates the manufacturing of motorcycle exhaust pipes through the hydroforming process, using FEM simulation (ABAQUS software), and calculates the optimal die geometry, required press force, and fluid pressure. Simulation results from ABAQUS demonstrate that the part is fully formed with an internal fluid pressure of 8.5 MPa and an axial load of 1120 kN.

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