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Hydroforming process of tube parts is widely used in many industries due to the virtues of weight reduction and high strength and stiffness. The exhaust pipe hydroforming process is investigated systemically combining FE simulation with experiments. The FE simulation model for hydroforming process is established after solving several key technologies based on the ABAQUS software, and the validation is carried out compared with experiments. And then, the effects of process parameters on forming quality are studied by using the FE simulation model. The optional process parameters are obtained based on the simulation model and orthogonal experimental analysis. Finally, three typical loading paths are proposed and tested, and the guidance for loading paths is given. Based on these developments, the exhaust pipes are manufactured by hydroforming in a short period at low cost.