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Based on ABAQUS platform, FE models for single and bi-layered U-shaped stainless steel bellows hydroforming were established, and the key problems in modeling were solved. Furthermore, dynamic explicit algorithm was adopted for the bulging stage and standard implicit algorithm was used for the springback stage, and the reliability of FE model was verified by comparing with the experiment results. The wall thickness distributions and bellow profiles of single and bi-layered bellows were comparatively analyzed. The changes of the wall thickness can be shown by the change rate of wall thickness, and the waveform size can be measured by change values of wave thickness, wave height and wave distance. The results show that wall thinning rate of the single layered bellow is higher than that of the bi-layered bellow, and for bi-layered bellow, wall thinning rate of its inner layer is higher than that of the outer layer. After springback, the dimension change of the bi-layered bellow is more obvious than that of the single layered bellow.
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