This paper addresses modeling and optimization of loading path in T-shape hydroforming of tubes using analysis of variance technique and Simulated Annealing (SA) algorithm. A set of experimental data has been used to assess the influence of loading process parameters in hydro-formed geometry. The process variables considered here include the yielding and expanding internal pressures and their required times, the calibration pressure, the axial and counter punches movements. The process output characteristics include thickness and height of protrusion. The Taguchi method and regression modeling are used in order to establish the relationships between the input and output parameters. Thirty two different cases for different loading paths are designed. The Abaqus/Explicit is used to calculate the minimum thickness and maximum height of protrusion. The adequacy of the model is evaluated using analysis of variance (ANOVA) technique. The proposed model is embedded into a Simulated Annealing (SA) algorithm to optimize the loading process parameters and to find the best input variables. Computational results prove the effectiveness of the proposed model and optimization procedure.

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