Variables Influencing Tubular Hydroforming

VARIABLES
INFLUENCING
TUBULAR
HYDROFORMING
Introduction
Tube hydrofoming is extremely utilized in automotive

industry.
Tube hydrofoming has cutting edge over other
forming operations.
Tube hydrofoming produces excellent result in the
manufacturing of hollow cross-section bodies.
By optimizing the process parameters suitably very
good results can be achieved .
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VARIABLES INFLUENCING
TUBULAR HYDROFORMING
Process description
Press closed and holding pressure
applied
COUNTER PUNCH
TOP PUNCH
HALF
SEAL
PUNCH
SCHEMATIC VIEW OF
EXPERIMENTAL SETUP
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BOTTOM DIE
HALF
3
Process description
End feed applied
SECONDARY
CONTOUR
SCHEMATIC VIEW OF
EXPERIMENTAL SETUP
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Process description
Opening press and ejecting component
T-JOINT
SCHEMATIC VIEW OF
EXPERIMENTAL SETUP
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Blank shapes
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Preforms
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Types of tube hydroforming

TUBE HYDROFORMING
FREE
HYDROFORMING
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TOOL DEPENDENT
HYDROFOMING
Die layout
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Tube properties affecting

Hydroforming
Predicting behavior of formability is difficult.
The effect of tube on hydroforming is expressed
by
1)
2)
3)
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corner radius
lubrication
end feed
10

Hydroforming
Test specimen:
size: O.D.= 76.2mm

material:
AKDQ(HR) -2.0mm
AKDQ(HR) -2.5mm
HSLA
-2.0mm
IF galvannel -2.0mm
IF galvanized-2.0mm
DP600
-2.0mm
lubricant:
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dry film lubricant (water-borne emulsion)/(0.04-0.05)

wet lubricant (mill oil 61-aus)/(0.15-0.2)
11

Hydroforming
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12

Hydroforming
Effect of tube expansion and corner radius:
lower strength materials expands better than higher

strength materials.
increasing end feed didnt produce consistent effect on
corner expansion
thinner gage expands well than thicker one
.
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13

Hydroforming
Effect of bursting pressure:
primarily influenced by material properties and wall

thickness.
effect of lubricant:
lubricant have negligible effect.
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14

Hydroforming
Conclusion:
tube characteristics (material properties and wall thickness)

have primary effect on corner expansion and bursting
pressure.
Friction condition (lubricant) affects wall thickness
distribution and failure location.
-Research carried out by

Industrial Research and
Development Institute
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15
Development of hydroform
technology
Objective:
to develop process sequence and material behavior.
test specimen:
O.D.
=63.5mm
thickness = 2.3mm
length
= 490mm
Y.S.
= 340MPa
T.S.
= 400MPa
elongation = 38.1%
lubrication = anti-corrosion oil / 0.07
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16
technology
pH=36MPa
axial stroke=40mm
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17
technology
Effect of loading path on thickness strain
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18
technology
Effect of loading path on corner radius
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19
technology
Result:
holding pressure must be high during axial feed (but

without bursting )
results in better final pressure and sectional shapes
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20
Influence tube material on

hydroforming
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21
Effect of material properties on

hydroforming allowance
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22
Effect of material properties on real

product
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23
Pillow hydroforming
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24
Advantages of Hydrofroming
Cost reduction by integration of components.

Weight reduction by reducing of welded flanges for
joining parts.
Improvement of fatigue properties by reduction of
welded joints.
Improvement of component strength by forming in a
closed sectional shape and work hardening.
Simplification of process by hole piercing in dies and
reduction of welded joints.
Reduction of spring back by plastic forming.
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25
Disadvantages of Hydroforming
Forming conditions are complicated, require greater

skill.
Forming machines are very large and expensive.
Cycle time is higher and productivity is low.
Spot welding of a product with other components is
difficult.
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26
Application
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27
Application
BUMPER BEAM AND ROOF RAILS
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28
Application
ROOF REINFORCEMENT
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29
Application
MANIFOLD INLETS
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30
Application
CHASIS STRUCTURE
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31
Cross-section
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32
Bibliography
1.
2.
3.
4.
5.
Metal forming handbook by SCHULER

Nippon technical report No.90 July 2004
Industrial research and development report
Tubular hydro forming of steel and
aluminum alloys.
www.vari-form.com
03-06-2005
33
Thank you

Variables Influencing Tubular Hydroforming

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Variables Influencing Tubular Hydroforming

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VARIABLES

Tube hydrofoming is extremely utilized in automotive

Types of tube hydroforming

Tube properties affecting

Tube properties affecting

size: O.D.= 76.2mm

dry film lubricant (water-borne emulsion)/(0.04-0.05)

Tube properties affecting

Tube properties affecting

Effect of tube expansion and corner radius:

lower strength materials expands better than higher

Tube properties affecting

Effect of bursting pressure:

primarily influenced by material properties and wall

lubricant have negligible effect.

Tube properties affecting

tube characteristics (material properties and wall thickness)

-Research carried out by

to develop process sequence and material behavior.

holding pressure must be high during axial feed (but

Influence tube material on

Effect of material properties on

Effect of material properties on real

Cost reduction by integration of components.

Forming conditions are complicated, require greater

BUMPER BEAM AND ROOF RAILS

Metal forming handbook by SCHULER

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