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In this paper, two design methods for T-shape tube hydroforming dies are proposed, namely, the extrusion-cutting-fillet method (ECFM) and the intersection-fillet method (IFM). Simulations on hydraulic expansion and axial feeding of T-shape tube hydroforming with two dies using the program DEFORM-3D were performed. The influence of the two dies on workpiece formability of T-shape tube hydroforming was examined. Experiments were carried out with SUS304 stainless steel tube at room temperature. A qualified product of T-shape tube, without wrinkling or bursting, was obtained using the die designed by the IFM method.

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