Hydroforming process is one of the newest metal forming methods that is gradually converted to the one of the most important forming methods. Compared to stamping, tube hydroforming offers higher part quality (tighter tolerances, increased rigidity) with lower manufacturing costs (reduced number of forming and assembly operations). In this study, the estimation of the process parameters for hydroforming Y-shapes, i.e. pressure levels, axial feeds, initial tube length, friction effect, mesh size effect and corner radius of protrusion effect on hydroformability of tube are discussed using ABAQUS 6.6-1. in simulation of process, effect of counter punch is applied show that using of counter punch can prevent failures during process, extremely. Then these estimated parameters are verified with hydroforming experiments. Finally some of These estimated parameters are then “optimized” using FEA simulations neural network genetic algorithms.
