European Journal of Scientific Research

ISSN 1450-216X Vol.68 No.3 (2012), pp. 377-388

EuroJournals Publishing, Inc. 2012
http://www.europeanjournalofscientificresearch.com


Effect of Heat Treatment Process on Hydroforming of
Tubular Materials


A. S. Selvakumar
Associate Professor, Department of Mechanical Engineering
B.S. Abdur Rahman University, Vandalur, Chennai, Tamilnadu, India

K. Kalaichelvan
Associate Professor, Department of Production Technology
M.I.T Campus, Anna University, Chennai, Tamilnadu, India

S. Venkataswamy
Former Professor, Department of Production Technology
M.I.T Campus, Anna University, Chennai, Tamilnadu, India
E-mail: selvakumar@bsauniv.ac.in


Abstract

Hydroforming uses the force of water or hydraulic fluids to shape a single part. A
pressurized fluid is introduced into ends of the tube. The applications of hydroforming are
in automobile, aerospace and sanitary use. Tube hydroforming is an advanced plastic
forming technology used in making complicated shaped hollow parts with thin wall. In tube
hydroforming process an internal fluid medium is used as a punch and the tube is bulged
into the desired shape through simultaneous application of axial feed and internal pressure.
This paper aims to evaluate the effect of deformation characteristics on tubular
materials before and after heat treatment in hydroforming process. The parameters
considered for experimental work are axial feed, fluid pressure, and fluid medium. Due to
effect of axial feed, the pressure during forming and expansion of tube were analyzed.
When pressure exceeds the limit, failures of wrinkle and bursting was occurred. It was
found that annealing would result in good formability of tubular materials.


Keywords: Formability, Annealing, Tube Hydroforming, Expansion Zone

1. Introduction
Hydroforming is one of the sheet-metal-forming technologies for making components with sheet metal
and tubular materials. In hydroforming method, the friction at the contact interface between the work
piece and die can be reduced and better formability of the product can be achieved (Yeong and Wen,
2005).Components produced by this process have been widely used in automotive and aerospace
applications (Lang et al, 2004). Exhaust system, chassis parts, power train components and seat frame
are among many components produced by hydroforming process (Muammer and Taylan, 2001).
Hydroforming can be used to make complex shaped sheet metal parts and tubular components.
In this process, sheet metal and tubular materials are deformed using pressurized fluid medium in
closed dies. In tube hydroforming, the fluid medium inside the tube serves as forming medium, and the
Effect of Heat Treatment Process on Hydroforming of Tubular Materials 378

tube is bulged into the desired shape through simultaneous application of axial feed and internal
pressure (Fillice et al, 2001). The combination of process parameters will produce the best quality part
in the minimum amount of time (Johnson et al, 2004). In order to achieve the economic product with
best performance, it is important to choose proper material and process selection (Carleer et al,
2000).The amount of axial feeding in coordination with internal pressure is a critical factor to improve
the formability of tubes(Ahmetoglu et al, 2000).
Buckling, wrinkling and bursting are the three failure modes that limit the expansion process in
hydroforming (Dohmann and Hart, 1996). Wrinkling occurs in tube hydroforming due to incompatible
relationship between internal pressure and axial feeding (Shijian et al, 2006). Bursting occurs when the
internal pressure is very high (Dohmann and Hart, 1997). Formability of the tube material was
evaluated by varying the process parameters. In our experimental work, a tubular specimen was placed
between the two halves of a split die and filled with oil or water as the forming medium. This tooling
was mounted on a hydraulic press as shown in Fig. 1. The punch was advanced into the tube to
increase fluid pressure and simultaneously for providing axial feed of the tube. The optimal expansion
zone geometry was identified by various experimental trials so as to achieve a flaw-free component.
Hydroforming offers many advantages in terms of improved structural integrity for the product,
reduction in production cost, material saving and reduction in the number of joining processes. Other
advantages of hydroforming include improved structural strength and stiffness, lesser tooling parts,
uniform thickness of formed component, lesser secondary operations, reduced scrap, reduced
dimensional variations, and weight reduction through more efficient section design (Ken-ichi and
Masaaki 2002).
The chemical analysis test for aluminum material (A9 6063) was carried out. Its chemical
composition is shown in Table 1.

Table 1: Chemical composition of aluminum A9 6063

Si Fe Cu Mn Mg Zn Ni Cr Pb Sn Ti Al
0.42811 0.35 0.0184 0.0249 0.4506 <0.0020 <0.0010 <0.0010 <0.0010 .0051 0.0056 98.77


2. Experimental Work
2.1. Hydroforming without Annealing Treatment
The experimental work was performed without annealing process on tubular materials of aluminum,
brass and mild steel. The die and punch were fabricated using low carbon steel as per dimensions
shown in Fig. 3. In the bottom surface of die cavity, a hole was made to enable measurement and
control fluid pressure inside the deformation zone. The test was carried out by placing the tube into the
die and filling the tube completely with SAE 90 fluid. The movement of punch provides both axial
feeding of the tube and increasing pressure inside the tube (Ahmetoglu and Altan, 2000). A Teflon
sealing was mounted on the front face of the punch which will be first to come in contact with the tube
to ensure necessary sealing to the system even when the pressure is quite high.
The die setup was mounted on a 100-ton hydraulic press for conducting experiments as shown
in Fig. 2. The parameters such as axial feed, pressure and fluid medium were considered to obtain
expansion zone geometry. The movement of punch increases the fluid pressure. The pressure can be
built up by compressing the fluid when the punch forces the blank downwards (Klaus et al, 2000). Due
to the development of high pressure, the desired shape of component may be obtained (Sokolowski et
al, 2000; Fuh-Kuo et al, 2007). The punch and die sketch with dimensions are shown in fig. 3.
In trial I, the experimental work was performed on aluminum, brass and mild steel tubular
materials of thickness 1.5 mm, length 106 mm and diameter 38 mm. The required bulging diameter of
tube was 54 mm. The punch axial feed for brass, aluminum and mild steel considered for experimental
work were 10 mm, 10 mm and 5 mm. The different pressures that developed during the forming
379 A. S. Selvakumar, K. Kalaichelvan and S. Venkataswamy

process were recorded and shown in Table 2. The failures were due to leakage of fluid through pipe
joints. The shape of formed component is shown in Fig. 5.
In trial II, different values of punch axial feed applied for aluminum were 10 mm, 13 mm and
15 mm. The values of pressure developed during the forming process are given in Table 3. The modes
of failure observed are wrinkling and bursting, which may be due to leakage of oil through pipe joints
and side wall of the tube. The formed components are shown in Fig. 6.
In trial III, after proper sealing by means of Teflon tape, leakage was arrested and experiments
were continued. The punch attachment of height 25 mm shown in Fig. 4 was fabricated and punch
axial feed of 25 mm was considered for experimental work. Due to increase in axial feed, the pressure
inside the tube increased, which initiated partial deformation. The results are shown in Table 4. The
formed components are shown in Fig 7.

Figure 1: Experimental setup in hydraulic press



Figure 2: Die setup view



Effect of Heat Treatment Process on Hydroforming of Tubular Materials 380

Figure 3: Punch and die sketch for bulging in hydroforming



Figure 4: Punch attachments of height 33 mm, 30 mm and 25 mm.


Trial I

Table 2: Effect of axial feed on brass, aluminum and mild steel tubes without annealing

Material of specimen: brass, aluminum and mild steel; length: 106 mm;
thickness of specimen: 1.5 mm; medium: SAE 90 Oil

S. No Material
Thickness
(mm)
Length
(mm)
Working
medium
Axial feed
(mm)
Pressure
(N/mm
2
)

Observation
1 Brass 1.5 106 Water 10 22.06 Wrinkle failure
2 Aluminum 1.5 106 SAE 90 Oil 10 15.85 Wrinkle failure
3 Mild steel 1.5 106 SAE 90 Oil 5 15.85 Wrinkle failure


381 A. S. Selvakumar, K. Kalaichelvan and S. Venkataswamy

Figure 5: Components with defects in wrinkling in trail I



Trial II

Table 3: Effect of axial feed on aluminum tube without annealing

Material of specimen: Al; length: 101 mm, 96 mm, 94 mm;
thickness of specimen: 1.5 mm, 1 mm and 0.7 mm; medium: SAE 90 Oil

S. No Material
Thickness
(mm)
Length mm
Working
medium
Axial feed
(mm)
Pressure
(N/mm
2
)

Observation
1 Aluminum 1 101 SAE 90 Oil 10 20.68 Wrinkling failure
2 Aluminum 1 96 SAE 90 Oil 13 19.30 Initiation of forming
3 Aluminum 1.5 94 SAE 90 Oil 15 20.30 Initiation of forming
4 Aluminum 0.7 96 SAE 90 Oil 13 18.2 Tear and buckling

Figure 6: Components with defects in trail II



Trial III

Table 4: Effect of axial feed on aluminum tube using punch attachment

Material of specimen: Al; length: 106 mm; thickness of specimen: 1 mm; medium: SAE 90 Oil

S.
No
Material
Thickne
ss (mm)
Length
(mm)
Working
medium
Axial feed
(mm)
Pressure
(N/mm
2
)
Observation
1 Aluminum 1 106 SAE 90 Oil 25 14.47 Partial deformation without defects.

Effect of Heat Treatment Process on Hydroforming of Tubular Materials 382

Figure 7: Components with partial deformation from trail III



2.2. Hydroforming after Annealing Treatment
The tubular materials of aluminum, brass and copper were annealed by heavy-duty electric furnace as
shown in Fig. 8. The annealing temperatures considered for aluminum, brass and copper materials
were 413C, 540C and 520C. The holding time in the furnace was 2 hours and then cooled. The
specifications of furnace are maximum temperature 1000, 6.5 kW and 230 V.

Figure 8: Annealing process in electric furnace



Trial IV: Effect of Axial Feed and Pressure
After ensuring no leakage in the set-up, experiments were carried out. The experiments were
performed by the movement of punch attachment into the tubular specimen of diameter 38 mm, length
106 mm and thickness 1.5 mm. The axial feed of the punch was 30 mm. After the formability test, the
tube was removed from the die and the diameter of expanded zone was measured to be 53.45 mm
using coordinate measuring machine. The formed component is shown in Fig. 9 and results are shown
in Table 5.

Table 5: Effect of axial feed on annealed aluminum tube using punch attachment

Material of specimen: Al; length: 106 mm; thickness of specimen: 1.5 mm; medium: SAE 90 Oil

S. No Pressure (N/ mm
2
) Axial feed (mm) Observation
1 10.29 30 Flaw-free deformation obtained
2 9.80 30 Flaw-free deformation obtained
383 A. S. Selvakumar, K. Kalaichelvan and S. Venkataswamy

Figure 9: (a) and (b) Components with uneven deformation



Trial V: Effect of Axial Feed and Pressure
In trial V, at an axial feed of 30 mm, pressure developed during forming was measured to be 10.78
N/mm
2
and better deformation was obtained. However, at an axial feed of 32 mm, a high pressure of
12.25 N/mm
2
was generated and thereby resulted in wrinkle defect of the component. The component
is shown in Fig. 10 and the results are shown in Table 6.

Table 6: Observations of trial V

Material of specimen: Al; length: 106 mm; thickness of specimen: 1.5 mm; medium: SAE 90 Oil

S. No Pressure (N/mm
2
)

Axial feed (mm) Observation
1 10.78 30
Better deformation in the expansion zone
but non-uniform thickness
2 12.25 32 Wrinkling failure

Figure 10: (a) and (b) Components with uneven bulging and wrinkle defects



Trial VI: Effect of Axial Feed and Pressure
In trial VI, when axial feed of 33 mm was applied, pressure developed was 19.60 N/mm
2
and wrinkle
defect occurred in the tubular component. The formed components are shown in Fig. 11. When axial
feed of 30 mm was applied, pressure developed during forming process was 9.6 N/mm
2
and the
required expansion zone geometry was obtained. The results are shown in Table 7.

Effect of Heat Treatment Process on Hydroforming of Tubular Materials 384

Table 7: Effect of axial feed on annealed aluminum tube using punch attachment

Material of specimen: Al; length: 106 mm; thickness of specimen: 1.5 mm; medium: SAE 90 Oil

S. No Pressure (N/mm
2
)

Axial feed (mm) Observation
1 19.6 33 Wrinkle defect
2 9.6 30 Required deformation obtained

Figure 11: (a) and (b) Components with defects of wrinkle and deformation



Trial VII: Effect of Axial Feed and Pressure
In trial VII, when axial feed of 30 mm was applied on brass specimen, a high pressure of 22.06 N/mm
2

was developed and bursting type of failure occurred. When axial feed of 30 mm was applied in copper
material, pressure developed was 16.54 N/mm
2
and better formability of bulging was obtained. The
formed components are shown in Fig. 12 and the results are shown in Table 8.

Table 8: Effect of axial feed on annealed brass and copper tubes using punch attachment

Material of specimen: brass and copper; length: 106 mm; thickness of specimen: 1.5 mm; medium:
SAE 90 Oil

S. No Pressure (N/mm
2
)

Axial feed (mm) Observation
1 22.06 30 Bursting failure occurred
2 16.54 30 Good deformation obtained

Figure 12: Component with burst failure and better deformation



385 A. S. Selvakumar, K. Kalaichelvan and S. Venkataswamy

Figure 13: Measurement of bulging diameter using coordinate measuring machine aluminum material



Figure 14: Measurement of bulging diameter using coordinate measuring machine brass and copper materials




3. Theoretical Pressure Calculations
The theoretical pressure required to deform the tubular work piece is calculated using the formula

3.1.1. Pressure Calculation
2
2 2 0
l n 0
0
3 3
n
r r
p k t
r r
| |
=
|
\ .

Where
k- Strength coefficient obtained from power law
r- Bulged tube radius = 27 mm
r
o
- Original tube radius = 19 mm
Effect of Heat Treatment Process on Hydroforming of Tubular Materials 386

t
0
- Original tube thickness = 1.5 mm
n- Strain hardening coefficient obtained from stress strain curve.
-True stress
- True strain

3.1.2. Power Law
= K
n

220 = K (0.15)
0.2292
220 = 0.647 K
K= 339.887 N/mm
2


3.2. Strain Hardening Exponent (n)
The strain hardening exponent noted as n, is a material constant which is used in calculations for stress-
strain behavior in work hardening.

Figure 3.1: Stress-Strain Curve of A9 6063



The values obtained from Stress-Strain curve are (0.15, 220) and (0.2, 235).
By plotting these values in log chart we obtain the value of n
n = (log 235 log 220) / (log0.2 log 0.15)
= 0.292.
The values of k ,r,r
o
, n,t
o
are substituted in the theoretical pressure formula.
P =2/3 * 339.837 (2/3 ln (27/19)
0.2292
*1.5 * (19/27
2
))
= 12.4 N/mm
2



4. Results and Discussion
The experimental work was performed using a split die to obtain expansion zone diameter of 54 mm
from 38 mm diameter aluminum tube (A9 6063) and brass, copper and mild steel materials. The
process parameters considered were axial feed, pressure and fluid medium.
387 A. S. Selvakumar, K. Kalaichelvan and S. Venkataswamy

The coordinate measuring machine (TESA Micro-hite 3D) shown in figure 13 and 14 was used
to measure bulging diameter of aluminum, brass and copper tubes. The specifications of the machine
were measuring range 460510420 mm, repeatability limit 0.3 m and air pressure 4.88.3 bar.
The experimental work was performed in two phases. In phase I, without heat treatment
process, three trials of experiments were carried out on brass, aluminum and mild steel tubes. Wrinkle
and bursting failures were observed on components in trial I and II. This was due to leakage of oil
through pipe joints and side wall of the tube.
For trials III to VII, in order to increase fluid pressure, punch attachments of height 33 mm, 30
mm and 25 mm were fitted on the punch face. This helped in arresting the leakage.
After arresting leakages, trial III was conducted using punch attachment of height 25 mm. A
bulging diameter of 42.904 mm was achieved.
In phase II, after annealing treatment to tubular specimens, four trials were performed using
punch attachments of heights 33 mm and 30 mm. Wrinkle failure and uneven bulging diameter were
observed initially due to high speed of the ram in trials IV and V. After reducing the speed of ram, the
desired diameter of 53.736 mm was obtained in trial VI.
In trial VII on annealed brass and copper tubes, the experimental work was performed to
evaluate the formability of tubular materials. A bulging diameter of 40.144 mm with bursting type of
failure was observed in brass tubular specimen due to improper ram speed. In copper material, a
diameter of 48.66 mm of deformed component was obtained.
By proper annealing treatment, leakage arresting and suitable punch movement, the desired
shape of the component without failure was obtained.


5. Conclusion
Hydroforming is an innovative forming process. It is becoming more popular in automobile and
aerospace Industries.
The experimental work was performed in two phases. In phase I, without heat treatment
process, three experimental trials were conducted, and wrinkling, bursting and initiation of bulging
formation were observed. The maximum bulging diameter obtained in phase I was 42.904 mm.
In phase II, after annealing treatment, four trials of experiments were performed. The required
bulging diameter was formed from trial VI in aluminum material at optimum parameters of axial feed
30 mm and pressure 9.6 N/mm
2
. The bulging diameter obtained was 53.735 mm.
Appreciable deformation was obtained for copper material from trial VII. The annealed
specimens showed good formability than those without heat treatment. Aluminum A9 6063 has good
formability and is a good candidate for tube hydroforming.
The pressure values obtained from experimental work are ranges from 9.6 N/mm
2
to 12.25
N/mm
2
and the theoretical pressure value obtained is 12.4 N/mm
2
.


Acknowledgements
The experimental work using hydraulic press was carried out at Department of Production Technology,
Anna University, MIT Campus, Chennai,India.The tubular specimen preparations, annealing treatment
process, tensile test by U.T.M and Measurements of bulging diameter by C.M.M f was carried out in
the Department of Mechanical Engineering, B.S.Abdur Rahman University, Chennai, India. The
authors thank the Departments of Production Technology,Anna university,M.I.T Campus and
Department of Mechanical Engineering, B.S.Abdur Rahman University for permitting to use all the
equipment facilities and providing all the technical support during the research work.


Effect of Heat Treatment Process on Hydroforming of Tubular Materials 388

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