Effects of Processing Parameters on Thickness Variation in Pressure Sequence Hydroforming

The tube hydroforming process is being used by the automotive industry to manufacture parts that are typically produced by stamping and welding processes. The advantages of tube hydroforming over conventional processing methods (i.e. stamping and welding processes) include part-consolidation, weight saving, and improved strength and stiffness of the formed structure. However, one of the drawbacks of the process is the incomplete knowledge base of the effects of processing parameters on the final product.

Two of the most significant parameters in the PSH process are the initial level of pressurization, and the amount of die displacement required to achieve the final shape. It is therefore the objective of this paper to investigate the effect of these two parameters on the final shape and thickness distribution in the tube. The paper presents the results of numerical models and experimental validation of these results.