Abstract
In this paper, the influence of tube material, microstructure, and heat treatment on process responses of tube hydroforming has been studied. One of the most important parameters in performing a successful tube hydroforming process is the selection of appropriate material for tubes. In the analysis section, effective parameters for the selection of an appropriate tube material for the hydroforming process have been investigated; it was concluded that higher strain hardening exponent (n), elasticity modulus (E), and anisotropy index (R) can enhance formability in this process; and the effects of microstructure and heat treatment on the formability of ASTM C11000 copper and ASTM AA1050 aluminum have been investigated. Consequently, four different heat treatment processes, which had different heating temperatures and durations, were selected, in addition to different cooling methods for each of the materials. In the experimental tests, the effects of these heat treatment methods on maximum bulging height, thickness strains, and final forming pressures were scrutinized. The effects of heat treatment on copper microstructure were also studied through metallographic tests; on the other hand, the effects of microstructure on tube hydroforming process were justified. As a result of these analyses, two heat treatment methods, namely, heating to 450 and 350 °C for 15 min and cooling in water, were recommended for copper and aluminum, respectively. Using these methods and due to their consequent fine and homogenous microstructure, higher mechanical strength and increase in material formability was achieved by attaining higher thickness strain and bulging height values. Finally, after extracting the mechanical properties of the two materials and comparing them with each other, parameters of strength coefficient and strain hardening exponent were reported as two effective factors that would improve tube deformation by tube hydroforming process.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Koc M, Aue-u-lan Y, Altan T (2001) On the characteristics of tubular materials for hydroforming—experimentation and analysis. International Journal of Machine Tool and Manufacture 41:761–772
Yuan SJ et al (2004) Hydroforming of typical hollow components. J Mater Process Technol 151:203–207
Manabe K, Amino M (2002) Effect of process parameters and materials properties on deformation process in tube hydroforming. J Mater Process Technol 123:285–290
Carleer B, van der Kevie G, de Winter L, van Veldhuizen B (2000) Analysis of the effect of material properties on the hydroforming process of tubes. J Mater Process Technol 104:158–166
Kridli GT, Bao L, Mallick PK, Tian Y (2003) Investigation of thickness variation and corner filling in tube hydroforming. J Mater Process Technol 133:287–296
Lei LP, Kim J, Kang BS (2002) Bursting failure prediction in tube hydroforming processes by using rigid-plastic FEM combined with ductile fracture criterion. International Journal of Mechanical Science 44:1411–1428
Kocanda A, Sodlowska H (2006) An approach to process limitations in hydroforming of X-joints as based on formability evaluation. J Mater Process Technol 177:663–667
Fatemi A, Biglari FR, Morovvati MR (2010) Influences of inner pressure and tube thickness on process responses of hydroforming copper tubes without axial force. Proceedings of the Institution of Mechanical Engineers Part B: Journal of Engineering Manufacture 224(12):1866–1878
Sang-Woo K, Woo-Jin S, Beom-Soo K, Jeong K (2009) Bursting failure prediction in tube hydroforming using FLSD. Int J Adv Manuf Technol 41:311–322
Jeong K, Sang-Woo K, Hoon-Jae P, Beom-Soo K (2006) A prediction of bursting failure in tube hydroforming process based on plastic instability. Int J Adv Manuf Technol 27:518–524
Ahmetoglu M, Altan T (2000) Tube hydroforming: state-of-art and future trends. J Mater Process Technol 98:25–33
Chandler H (ed) (1996) Heat treater’s guide: practice and procedures for nonferrous alloys. ASM International, Novelty, OH
ASM (1991) ASM handbook, vol. 2: properties and selection: nonferrous alloys and special-purpose materials, 10th edn. ASM International, Novelty, OH
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Fatemi, A., Morovvati, M.R. & Biglari, F.R. The effect of tube material, microstructure, and heat treatment on process responses of tube hydroforming without axial force. Int J Adv Manuf Technol 68, 263–276 (2013). https://doi.org/10.1007/s00170-013-4727-1
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-013-4727-1