Experimental and numerical simulation of tube hydroforming (THF)

Hydroforming is a manufacturing process that uses a fluid medium to form a part by using high internal pressure. In tube hydroforming (THF), a tubular blank is placed between two dies, sealed and filled by injecting pressurized water up to 1200 MPa into it, deforming its walls and calibrating them to shape the die cavities. The advantages of the hydroforming over the traditional process are: (a) light weight constructions; (b) design flexibility increase, enable new shapes; (c) stiffness increase by using no welded tubular blanks; (d) welded assembly elimination; (e) dimensional accuracy. The weight reduction obtaining by THF can be aided by further reduction trough lighter materials selection. This paper aims to establish a basic understanding of the THF processing of aluminum and copper tubes. The THF is briefly reviewed by carrying out an FEA of 2 THF processes. The first simulation case is the THF of a free aluminum tube without thrust feed force. The second one is a study of THF calibration into a closed die. Finally, some preliminary results on the design and development of THF facility as well as its control are presented with some experimental results, looking for a THF process window.