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The process of hydroforming is defined as the formation of parts into the internal mold design using internal pressure. This process can extensively reduce parts and secondary operations, and adoption to the loading path is one of its most essential points. The purpose of this paper is to address these issues.

A dynamic loading path was taken into account in the current study, and a drop hammer was employed for this purpose, decreasing the time and requiring less number of systems.

One of the main observations of this research is that selecting side punches with a smaller central hole radius is proportional to the kinetic energy and the amount of fluid. Moreover, it can be effective in achieving the optimal loading path.

In addition to experiments for numerical analyses, the finite element simulation model was provided via Abaqus software in which the Eulerian–Lagrangian coupling method was utilized for evaluating the tube forming process through repeating the fluid flow formation because of the effect. Moreover, the genetic programming model was efficient for determining the most suitable input parameters regarding prediction for the minimum thickness which examined the efficiency of the process and presented a mathematical relationship.