Experimental and numerical investigation of hydro-forming of stepped tubes for aluminum alloy 6063

Mehdi Safari, Javad Salimi, Saeid Hamidipoor


In this work, hydro-forming of stepped tubes for aluminum alloy 6063 is investigated experimentally and numerically. Experimental investigations are performed using a die set with new design in bush driving mechanism. Also, numerical simulations are done with finite element software, Abaqus 6.14-4. In the experiments, a new mechanism is proposed for production a stepped tube with sharp corners and high expansion ratio. Also, the effects of some process parameters such as internal pressure, die stroke and friction coefficient on filling of the die and also minimum wall thickness are investigated. The results show that using the proposed mechanism in this paper, a stepped tube with sharp corners and high expansion ratio can be manufactured. Also, it is concluded that better filling of the die is happened with an increase in the die stroke and internal pressure. Also, the reduction of wall thickness is increased with increasing the die stroke, internal pressure and friction coefficient.


H.S. Kim, M.D. Sumption, H.J. Bong, H. Lim, E.W. Collings, Development of a multi-scale simulation model of tube hydroforming for superconducting RF cavities, Materials Science and Engineering: A, Volume 679, 2 January 2017, Pages 104–115.

Y. Shi, H. Jin, P.D. Wu, D.J. Lloyd, Effects of superimposed hydrostatic pressure on necking and fracture of tube under hydroforming, International Journal of Solids and Structures, Volumes 113–114, 15 May 2017, Pages 209–217.

S.J. Hashemi, H. Moslemi Naeini, G.H. Liaghat, R. Azizi Tafti, Prediction of bulge height in warm hydroforming of aluminum tubes using ductile fracture criteria, Archives of Civil and Mechanical Engineering, Volume 15, Issue 1, January 2015, Pages 19–29.

Farshid Hajializadeh, Mahmoud Mosavi Mashhadi, Investigation and numerical analysis of impulsive hydroforming of aluminum 6061-T6 tube, Journal of Manufacturing Processes, Volume 20, Part 1, October 2015, Pages 257–273.

R. Bihamta, Q.-H. Bui, M. Guillot, G. D’Amours, A. Rahem, M. Fafard, Global optimisation of the production of complex aluminium tubes by the hydroforming process , CIRP Journal of Manufacturing Science and Technology, Volume 9, May 2015, Pages 1–11.

Jiyuan Liu, Zicheng Zhang, Ken-ichi Manabe, Yanmei Li, R.D.K. Misra, Microstructure evolution in TRIP-aided seamless steel tube during T-shape hydroforming process, Materials Characterization, Volume 94, August 2014, Pages 149–160.

Xiao-Lei Cui, Xiao-Song Wang, Shi-Jian Yuan, Deformation analysis of double-sided tube hydroforming in square-section die, Journal of Materials Processing Technology, Volume 214, Issue 7, July 2014, Pages 1341–1351.

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.

Hwang Y-M, Chen W-C (2005) Analysis of tube hydroforming in a square cross-section die. Int J of Plasticity 21:1815–1833.

Loh-Mousavi M, Mori K, Hayashi K, Bakhshi-Jooybari M (2007) Improvement of filling die corners in box-shaped tube hydro-forming by control of wrinkling. Key Engineering Materials 334:461–467.