Multi-layered tube hydro-forming is suitable to produce multi-layered joints to be used in special application in many industries. With using a middle layer of foam and making sandwich structures, tube bending strength increases when external loads are applied. Also because of the foam is high energy absorption, in the pipelines of major industries such as the nuclear, strength increases when natural disasters, especially earthquakes happen. In this paper for the first time, three-layered new sandwich tube (inner layer of copper, middle layer of aluminum foam and outer layer of annealed brass) hydroforming processes were numerically simulated using finite element method by ABAQUS/Explicit 6.10. As the result of three-layered sandwich tube hydro-forming not reported in the literature, the results of this paper are compared with the latest experimental result of bi-layered tube hydro-forming find in literature by approaching the thickness of middle layer to zero. Finite element analysis shows that numerical and experimental results have a good agreement
