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This paper is concerned with the numerical simulation of sheet metal forming with special attention to the simulation of hydroforming processes. The simulations are carried out with explicit finite element methods, using both deformable (tube) and rigid (dies) material models. It has been shown that the explicit finite element method is an efficient method to solve hydroforming problems, in particular when increasing loading rate, mass scaling, system damping and interface damping techniques are utilised.
Inaccuracies can have their origin in fundamental errors within the basic material laws, but also because the elastic-plastic transition and the friction behaviour are not modelled accurately. The elastic part of the material law, mostly combined with an early re-plastification, plays an important role in estimating the adjusting accuracy tolerances. Therefore, sophisticated theories have to be installed in FE-codes. Several types of material laws have been investigated for their suitability for hydroforming operations, especially in the use of aluminium alloys for the lightweight construction in the automotive industry, e.g. the body in-white or axle components. The numerical and experimental results agree well.

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