IJAMS

RECENT DEVELOPMENT OF HYDROFORMING-A

REVIEW
F. Forouhandeh1, S. Kumar2, S. N. Ojha3
1
Department of Engineering, Shahrood Branch, Islamic Azad University, Shahrood, Iran
fariborzforouhandeh@gmail.com
2
Department of Mechanical Engineering IIT BHU
santosh.kumar.mec@itbhu.ac.in
3
Department of Metallurgical Engineering IIT BHU
ojha_bhu@yahoo.co.in
Abstract: Hydroforming is one of the recent forming technologies in which hollow tubes (THF) and sheet work pieces (SHF) are
formed under high fluid pressure. Sheet hydroforming (SHF) process is found to be special one for different kind of sheet metal
component manufacturing. Hydroforming has been a major field of interest for engineering and scientific research as well as
designers, developers to look for its optimal process in terms of surface quality and part consolidation. Most of the papers reviewed
herein relate to modeling and simulation of the process and the various issues such as process parameters, and experimental study of
different alloys. In this paper, the review of various aspects of research on sheet and tube hydroforming process has been presented.
Finally, scope of possible work that is going to be done has been introduced.
Keywords: Sheet hydroforming, Tube hydroforming, Finite element method

1. Introduction
Metal forming of light alloys has become very
popular due to high strength to weight ratio
product formation by forming processes.
Automobile, Sanitary, aerospace etc are very
common due to the capability of light alloys to be
formed in variety of shapes by variety of forming
operations. Hydroforming has become very
popular forming process today to meet the
challenges of these industries. Tube hydroforming [THF] and sheet hydro-forming [SHF]
are relatively complex manufacturing process.
The process is better than the conventional
manufacturing via stamping and welding such as:
(i) Part consolidation resulting in weight reduction
of the component, (ii) weight reduction through
more efficient section design and tailoring of the
wall thickness, (iii) reduced tooling cost, (iv)
improved structural strength and stiffness, (v) less
number of secondary operations, (vi) reduced
dimensional variation, (vii) significant reduction

in spring back effects and (viii) reduced scrap rate.

The analysis and performance of the process
depends on many factors such as part geometry
and design, material and process parameters and
the boundary condition of forming.
The best and easy way to study the behavior of the
process for these alloys is by Finite Element
method and Computer Aided Engineering based
procedure.
The
technology
of
product
manufacturing by THF and SHF is developing
very fast to shape complex profiles of products.

2. Principles in hydroforming
The working principle for sheet hydroforming is
shown in figure1 as an example. After blank
setting and blank holding, when the punch pushes
the sheet metal into the die cavity, within which
oil or other liquids are contained, high pressure
that can press the sheet metal tightly onto the
punch will be generated. Then, the effect of

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F. Forouhandeh, S. Kumar, S. N. Ojha

friction retention is affected. At the same time the

liquid in the die cavity will flow out between the
upper surface of the die and the sheet metal.
Therefore, fluid lubrication that will reduce
frictional force is produced.
Tube hydro-forming is a process of forming
closed and hollow section of different crosssections by applying an internal hydraulic
pressure in conjunction with end axial feeds. A
tube is placed in the tool cavity, whereby the
geometry of the die corresponds to the external
geometry of the produced part (figure2). These
tools, in most cases separated in longitudinal
direction, are closed by the ram movement of a
press, and the tube ends are loaded by two
punches moving along the tube axis. Each of the
loads applied to the tube ends for sealing the
tubes interior must be at least equal to the force
calculated from the product of the tubes internal
area and the tubes internal pressure. However, the
axial forces may be increased to a higher value if
the forming job requires it and then the additional
tube wall material is brought into the tool cavity.
Internal pressure is increased during the process
until the expanding tube wall comes into contact
with the inner surface of the die cavity. This
principle may be used for hydroforming both
straight and pre-bent tubes. Screw and hydraulic
presses can be used for hydroforming. They
should have speed controller and displacement
measurement accommodations.
Figure 3 shows various hydroforming processes
and its applications. Figure 4-7 shows schematic
of different types of sheet hydroforming process.
Table 1 shows common products for
hydroforming.

3. Main
review
work
hydroforming process

of

sheet

There are some investigations about Sheet

hydroforming like Zhang. et.al.[1] investigated a
brief review of recent developments in the area of
hydroforming and their relevant history with
process variations for forming tubular and flat
components. Applications of shell type products
have also been reported in most of German
aircraft.

Hein.et.al.[2] carried out an investigation about

hydroforming of sheet metal pairs and numerical
and experimental study wherein Hydroforming of
sheet metal pairs (a new class of HF) has also
been investigated concerning different models,
simulations and experiments on unwelded sheet
metal pairs. It is found that numerical simulations
and experimental study influence various
parameters on the process feasibility and the result
of experiments confirmed the FEM simulations
results.
Novontny. et.al.[3] carried out an investigation
about SHF of Al-alloys (AA6016-T4) and
illustrated the advantages of SHF over other
alloys. It is formed that SHF of Aluminum alloy
has good mechanical properties.
Zhang. et.al.[4] proposed a movable die for SHF
process and carried out numerical and
experimental study to improved the forming
characteristics of alloys. The limit drawing ratio
of the sheet was improved. This process is
especially suitable for forming of small batch
production of sheet metal parts with complicated
shapes.
Zampaloni. et.al.[5] carried out numerical and
experimental
investigations
in
stamp
hydroforming by using pressurized viscous
fluid.(for aluminum(3003-H14-Aluminum) alloy).
Wherein, one or both surfaces of the sheet metal
are supported with a pressurized viscous fluid to
assist with stamping of the part thus (no need to
female die). The pressurized fluid has several
purposes: a) Supports the sheet metal from the
start to the end of the forming process ,thus :
better deformation. b) Delays the onset of
material failure. c) Reduces wrinkle formation.
Experiments, shows draw depths improvements
up to 31% before the material failed.
Zhang. et.al.[6] has carried out a new SHF
technology using a movable die comparing
between THF and SHF and used a movable
female die in SHF. Where in SHF technology are
summarized w.r.t increase in the feeding of
materials and local deformation capacity for SHF.
Development of SHF technology is still much
slower than THF technology.

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Recent Development Of Hydroforming-A Review

Nielsen et.al. [7] investigated resent development

of SHF for lightweight components and expressed
the requirements of press control equipments.

including high drawing ratio, wall thickness

distributions, free wrinkling and fracture were also
discussed.

Lang et.al. [8] carried out numerical and

experimental research about application of viscous
pressure forming(VPF)for non-symmetric steel,
aluminum and nickel parts. FEM simulation and
blank holding force control was used for
optimization the process conditions. It has been
discussed effect of process variables upon the
achievable part geometry. Comparison between
FEM results and experiments illustrated
simulation was used to predict material flow with
high accuracy.

Hama. et.al.[12] carried out numerical and

experimental study on elliptical deep drawing
using an elastoplastic FEM (code STAMP3D)
program. Where in simulated result could predict
experimental result about the thickness strain
distribution.
The
comparison
between
conventional process and SHF process
(numerically and experimentally shows that SHF
gives better formability.

Merklein. et.al.[9] carried out numerical and

experimental study for joining tube and double
sheet in hydroforming. Both of tube and sheets
were formed simultaneously jointed. The finite
element analysis and laboratory trials were used to
design the die cavity so as to avoid the wrinkling
of material tearing and the collapsibility of the
tube section during forming. The analytical model
of the author predicts the experiment conditions
well.
Abedrabbo. et.al.[10] carried out an important
investigation about wrinkling behavior of
Aluminum alloys during SHF. In this research
FEM and experimental study have been
implemented for 6111-T4 aluminum alloy. It
shows that, the use of pressurized fluid delays the
onset of material rupture and acts as a blank
holding force to control wrinkling in the flange
area. An optimum fluid pressure profile generated
by FEM was applied in SHF to make the deepdrawn hemispherical cup without tearing and with
minimal wrinkling in the flange area. The FEM
model predicts the location of the material rupture
in pure stretch and wrinkling characteristics of the
Aluminum alloy sheet.
Lang. et.al.[11] carried out numerical and
experimental study of hydromechanical deep
drawing (HDD) by using very thin middle layer in
multi-sheet hydroforming. The main advantage of
SHF has been to be uniform pressure transferred
to everywhere. Some features on the formed
forced internal, external and middle layers

Murr. et.al.[13] carried out investigation about

metallurgical and microstructural characterization
of a hydro formed steel part. Microstructural
characterization by light optical metallography
(LOM) and transmission electron microscopy
(TEM), (including grain structures) was carried
out. Hojjati. et.al.[14] simulated super plastic
forming in hydroforming process. The
investigation of Aluminum alloy 5083 in
hydroforming process was simulated at three
different constant pressures, and effect of pressure
on thickness distribution and final dome height
were evaluated. Paper shows the work on
Titanium alloys (Ti-6Al-4V,Ti-6Al-2Sn-4Zn2Mo) and
Aluminum alloys (5083,7475)are
typical examples of metallic super plastic
materials. It is observed that Low flow stress and
high sensitivity of flow stress to strain rate are the
main feature of super plastic deformation.
Swadesh Kumar Singh and D. Ravi Kumar et.
al.[15] carried out studies to see the effect of
process parameters on product surface finish and
thickness variation in hydro-mechanical deep
drawing. Anup K. Sharma and Dinesh K. et.
al.[16] carried out Finite element analysis and
experimental study on sheet Hydro mechanical
forming of circular cup by using LS-DYNA.
F. Forouhandeh, S. Kumar, S. N. Ojha and B.
Nahak et. al.[17] fabricated setup of SHF and
tested for Aluminum, Copper and Brass sheets.
Advantage of sheet hydroforming process in
comparison to conventional deep drawing has
been illustrated using microstructure analysis.

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Table 2 shows literature review of sheet

hydroforming and contribution of any author in
this work.

4. Main
review
work
hydroforming process

of

Tube

The work reported by Woo et. al.[18] incorporate

experimental and analytical result for tubes bulged
under internal pressure and axial compressive
loading under a numerical study assuming the
entire length of the bulged tube to be in tension
and thus, free bulging took place. The comparison
of experimental and theoretical results indicated
good agreement when stress-strain properties of
tubes obtained from bi-axial tests were used in
calculations. Limb et. al.[19] used oil as the
pressurizing medium in their experiments to
investigate forming of copper, Aluminum, low
carbon steel and brass Tee-shaped tubular parts.
Results with different lubricants and material
evaluations were reported in terms of protrusion
height attainable. Sauer et. al.[20] presented the
theoretical and experimental work on necking
criterion of bulged tubes.
Woo [21] , Woo and Lua [22] described their
experimental tooling and presented their
theoretical analysis based on the stresses and
strains taking into account the anisotropy effect of
the sheet metals in separate papers. Manabe and
Nishimura [23] investigated the influence of
strain-hardening exponent and anisotropy on the
forming of tubes in hydraulic bulging and nosing
processes. They briefly presented the maximum
internal pressure as a function of tube radius,
thickness, strain hardening exponent, and strength
coefficient assuming no axial loading. Manabe et.
al.[24] worked on deformation behavior and
examined the limits of forming for Aluminium
tubes under both internal pressure and axial force.
Axial cylinders and internal pressure were
controlled by a computer-control-system to obtain
predefined stress ratio during their experiments.
Fuchizawa et. al.[25] analyzed the bulge forming
of finite-length, thin-walled cylinders under
internal pressure using incremental plasticity
theory.

Nader et. al.[26] used analytical models to see the

limits of free forming and the influence of
different material and process parameters on
loading path and the corresponding forming limit
result. It was also pointed on the type of
experimental investigation to be carried out for
hydroforming.
Li-Ping Leia et. al.[27] developed a FEM program
HydroFORM-3D for analyzing and designing
the tube hydro formed parts for automobile rear
axle housing and sub-frame. Ray and Donald [28]
conducted experimental studies for X- and Tbranch components for different loading paths
(forming pressure and axial feed) via data
acquisition system integrated with THF machine
and compared the results with simulation values.
There have been efforts to help industry people by
developing a Computer aided process planning
system (CAPPS[29,30]) for THF products.
Table 3 shows most of literature review of tube
hydroforming and contribution of any author in
this work.
Nowadays, commercially pure Titanium (CP Ti)
is being paid much attention due to its properties
of lightness, high specific ratio of strength to
weight, strength against high temperature, antirust and good adaptability for a living body. Sheet
hydroforming of CP Ti sheets is especially
important for the production of thin-walled
structural components used in the electronics and
aerospace products, such as the cover cases of
notebook and camera, mobile phone. But low
ductility, high spring back and sensitivity against
atmosphere elements especially Oxygen above
recrystalization temperature of Titanium makes
some limitations for any kind of metal forming. F.
Forouhandeh, S. Kumar, S. N. Ojha and Parkash
T. O. [31] carried out modeling of sheet
hydroforming process for Commercially Pure
Titanium grade 1for cup shape products and
optimized the process in terms of defect free
products. DEFORM3D package has been used for
finite element simulation and parametric study.

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Recent Development Of Hydroforming-A Review

5. Conclusion
Literature review of sheet hydroforming and tube
hydroforming has been carried out. Most of the
works include review of developments about SHF
& THF, Numerical(FEM based analysis) and
experimental study of SHF & THF process;
propose of some new method such as using
female die in SHF, investigations about SHF of
Aluminum alloys and optimization of SHF like
avoiding of tearing and wrinkling during process
and avoiding of bursting and thinning during
THF. But there are some challenges such as
optimization of process parameters related to SHF
of CP Titanium and Titanium alloys and its
experimental study. Also microstructure analysis
of hydroformed Titanium parts is an area which is
still to be exploded in the field of sheet
hydroforming process.

Figure 4: Hydro mechanical deep drawing [9]

Figure 5: Hydraulic stretch forming [8]

Figure 1: Schematic of the sheet hydroforming
process: (a) blank setting; (b) blank holding; (c)
drawing and (d) finishing [9]

Figure 2: Tube hydroforming: 1, tube 2, lower die 3,

upper die 4, axial punch [9]
Figure 6: Hydroforming using a membrane Diaphragm
[8]

Figure 3: Various hydroforming processes and its

applications [9]

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F. Forouhandeh, S. Kumar, S. N. Ojha

Figure 7: Double blank hydroforming [8]

Table1: Common products of hydroforming

Table2: Literature review of SHF

Issues
Review of developments

Year
1999
2004

Author
Zhang
Zhang

Sheet hydroforming of
aluminium alloys

2001

Novotny

2005

Farhang
Pourboghrat
Farhang

Experimental and numerical

1999

Contribution
review of developments
Developed of SHF technology by using
movable die
Developed of sheet metal pairs from
aluminium alloys
Developed of wrinkling control of SHF of AL
alloys
Developed of hydroforming of sheet metal

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Recent Development Of Hydroforming-A Review

study of SHF
2003

Pourboghrat
M.Zampaloni

2005

Lihui Lang

2007

Takayuki Hama

2004

L.H.Lang

2005

M.Geiger

2003

Shi-Hong Zhang

2004

Taylan Altan

2006

Lihui Lang

Microstructure

2008
2008

M.H.Hojjati
L.E.Murr

Experimental study

2008

Swadesh Kumar
Singh

Investigation of effect of process parameters

on product surface finish

Experimental and numerical

study of SHF
Experimental study and
microstructure analysis

2009

Anup K. Sharma

2012

F. Forouhandeh &
S. Kumar

Experimental and numerical study of SHF of

circular cup
Microstructure analysis of sheet hydroformed
light alloys

Numerical study and

optimization

2012

F. Forouhandeh &
S. Kumar

Comparison between SHF

and THF

Optimization of material flow

and propose new method

pairs
Developed of stamp hydroforming of sheet
metals
Developed of multi-layer SHF by using the
very thin layer in the middle
Developed of elliptical cup deep drawing by
SHF
Investigate of classifications and its
characteristics
Developed of SHF and THF for manufacturing
of complex parts
Developed of SHF by using a movable female
die
Developed of SHF by using a viscous pressure
medium
Developed of SHF by using a optimized model
about tool dimensions and friction coefficient
Developed of SHF of superplastic
Investigation of metallurgical characterization
of a hydroformed steel part

Modelling of SHF process of CP Titanium

Table3: Most of the literature review of THF

Issues
Experimental and numerical
study of THF

Analysis and experimental

study of THF

Parametric study

History presentation

Year
1973

Author
Woo

1976

Limb

1978

Sauer

1978

Woo

1983

Manabe

2001

Li-Ping Leia

2005

Ray

Contribution
experimental and analytical study for tubes
bulged under internal pressure
Development of T branch products of Brass
and Cu
Theoretical and experimental work on necking
criterion of bulged tubes
Investigation of anisotropy effect of the sheet
metals for THF
Investigation of influence of strain-hardening
exponent and anisotropy on the forming of
tubes in hydraulic bulging
Analyzing and designing the tube hydro
formed parts for automobile rear axle housing
Studying in T and X branch THF

1999

S.H.Zhang

Recent development and history

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F. Forouhandeh, S. Kumar, S. N. Ojha

Analysis, numerical and

experimental study
Computer aided process
planning

1999

P.Hein

Investigation about hydroforming of sheet

metal pairs

2007

Sarang & S. Kumar

CAPP of rapid prototyping

2008

Sreenivasulu & S.
Kumar

Generative CAPP for THF

Hydroforming of sheet metal using a

viscous pressure medium, Journal of
Materials Processing Technology, 146, 97107.

6. References
1.

Zhang S. H., 1999, Developments in

hydroforming , Journal of Materials
Processing Technology, 99, 236-244.

2.

Hein P. and Vollertsen F., 1999,

Hydroforming of sheet metal pairs,
Journal
of
Materials
Processing
Technology, 87, 154-164.

3.

Novotny S. and Hein P., 2001,

Hydroforming of sheet metal pairs from
aluminum alloys, Journal of Materials
Processing Technology, 115(1), 165-69.

4.

Zhang S. H., Zhou L. X., Wang Z. T., Xu

Y.,
2003,
Technology
of
sheet
hydroforming with a movable female die,
International Journal of Machine Tools and
Manufacture, 43, 781-785.

5.

6.

Zampaloni M., Abedrabbo N., Pourboghrat

F., 2003, Experimental and numerical
study of stamp hydroforming of sheet
metals,
International
Journal
of
Mechanical Science, 1815-1848.
Zhang S. H., Wang Z. Xu R., Y., Wang Z.
T., Zhou L. X., 2004, Recent developments
in sheet hydroforming technology, Journal
of Materials Processing Technology , 237241.

7.

Nielsen K. B., 2004 Hydroforming

highlights:sheet hydroforming and tube
hydroforming, Journal of Materials
Processing Technology, 155, 165-177.

8.

Lang L. H., Wang Z. R., Kang D. C., Yuan

S. J., Zhang S. H., Danckert J., Ahmetoglu
M., Hua J., Kulukuru S., Altan T., 2004,

9.

Merklein M., Geiger M., Celeghini M.,

2005, Combined tube and double sheet
hydroforming for the manufacturing of
complex parts, Journal of Manufacturing
Technology, 54, 199-204.

10.

Abedrabbo N., Zampaloni M. A.,

Pourboghrat F., 2005, Wrinkling control in
aluminum
sheet
hydroforming,
International Journal of Mechanical
Science, 43, 333-358.

11.

Lang L., Danckert J., Nielsen K. B., 2005,

Multi-layer
sheet
hydroforming:
Experimental and numerical investigation
into the very thin layer in the middle,
Journal
of
Materials
Processing
Technology, 170, 524-535.

12.

Hama T., Hatakeyama T., Asakawa M.,

2007, Finite element simulation of the
elliptical cup deep drawing process by sheet
hydroforming, finite elements in analysis
and design, Journal of Material
Characterization, 43, 234-246.

13.

Murr L. E., Gayton S. M., Lopez M. I.,

Bujanda D. E., 2008, Metallurgical
characterization of a hydroformed, 304
tainless steel, Caribbean-style musicalpan,
Journal of Material Characterization, 59,
321-328.

14.

Hojjati M. H., Zoorabadi M., Hosseinpour

S. J., 2008, Optimization of superplastic
hydroforming process of Aluminum alloy

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Recent Development Of Hydroforming-A Review

5083, Journal of Materials Processing

Technology, 205, 482-488 .
15.

16.

Kumar Singh S. and Ravi Kumar D., 2008,

Effect of process parameters on product
surface finish and thickness variation in
hydro-mechanical deep drawing, Journal
of Materials Processing Technology, 204,
169178.
Anup K. Sharma, Dinesh K, 2009, Finite
element analysis of sheet Hydromechanical
forming of circular cup, Journal of
Materials Processing Technology, 209,
14451453.

24.

Manabe K., Mori S., Suzuki K. and

Nishimura H., 1984, Bulge forming of
thin-walled tubes by micro-computer
controlled hydraulic press, Advance
Technology Plasticity, 1, 279.

25.

Fuchizawa S., 1984, Influence of strain

hardening exponent on the deformation of
thin-walled tube of finite length subjected to
hydrostatic external pressure, Advance
Technology Plasticity, 1, 297.

26.

Asnafi N., 1999, Analytical modeling of

tube hydroforming, Journal of Thin-Walled
Structures, 34, 295.

17.

Forouhandeh F., Kumar S., Ojha S. N.,

Nahak B., 2012, Development of a Sheet
Hydro forming setup and product
characterization, 4th International and 25th
All India Manufacturing Technology,
Design
and
Research
Conference,
(AIMTDR), 2, 696-700.

27.

Leia Li-Ping, Kima Dae-Hwan, Kangb

Sung-Jong, Hwanga Sang-Moon, Kang
Beom-Soo, 2001 Analysis and design of
hydroforming processes by the rigidplastic
finite element method, Journal of
Materials Processing Technology, 114, 201.

18.

Woo D. M., 1973, Tube-Bulging under

Internal Pressure and Axial Force, Journal
of Materials Processing Technology, 95,
219.

28.

Ray P. and Mac Donald B.J., 2005,

Experimental study and finite element
analysis of simple X- and T-branch tube
hydroforming processes, International
Journal of Mechanical Sciences, 47, 1498.

19.

Limb M. E., Chakraborty J., Garber S.,

Roberts W. T., 1976, Hydraulic Forming
of Tubes, Sheet Metal Industries, 418.

29.

Sarang S. Pande and Kumar S., 2008, A

Generative process planning system for
parts produced by Rapid prototyping,
International journal of Production
Research, 46(22), 643.

30.

Sreenivasulu B., 2007, Analysis and

Simulation of Hydroforming Process
Unpublished M.Tech. Thesis, IT-BHU
Varanasi INDIA), 13.

31.

Forouhandeh F., Kumar S., Ojha S. N.,

Parkash T. O., 2012, Modeling of Sheet
Hydroforming of CP Titanium for
semispherical
cup
shape
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International Journal of Modeling and
Simulation in Design and Manufacturing
(JMSDM),3, 47156.

20.

Sauer W. J., Gotera A., Robb F., Huang P.,

1978, Free Bulge Forming of Tubes under
Internal Pressure and Axial Compression,
Proceeding of the Sixth NAMRC, 228.

21.

Woo D.M., 1978, Development of a bulge

forming process, Sheet Metal Industries,
623-625.

22.

Woo D.M., 1978, Lua A., Plastic

deformation of anisotropic tubes in
hydraulic bulging, Journal of Materials
Processing Technology, 100, 421.

23.

Manabe K. and Nishimura H., 1983

Influence of material properties in forming
of tubes, Bander Bleche Rohre, 9.

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F. Forouhandeh, S. Kumar, S. N. Ojha

Biography
Fariborz Forouhandeh is Ph.D. Scholar in
Department of Mechanical
Engineering IIT BHU, also a
faculty member (lecturer) in
department of engineering,
Islamic
Azad
University,
Shahrood branch, Iran. He has
Master degree in Mechanical
engineering, production and
manufacturing from University of Science and
Technology of Iran.
Santosh Kumar is Professor in Department of
Mechanical Engineering IIT
BHU. He has Ph.D. degree
from IIT Kanpur. He is a
fellow of Institution of
Engineers (India). He is
working
in
area
of
manufacturing.

S. N. Ojha is Professor in Department of

Metallurgical Engineering
IIT BHU. He is program
coordinator
in
this
department. He is a fellow of
Indian Institute of Metals,
Institution of Engineers and
Life Member, in Materials
Research Society of India.

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