Strain analysis of AA6063 aluminum alloy by tube hydroforming process

Abstract

Tube hydroforming process is used to create parts from aluminum extrusions which reduce structural weight. Different approaches for the formability improvement in the hydroforming process are summarized. In this work, extruded aluminum (annealed) tubular specimen made up of AA 6063 alloy bulged from the diameter of 38–54 mm using hydroforming technique. The objective of this work is to analyze thickness distribution at bulging region along lateral (x) and longitudinal (y) directions. The parameters considered are axial feed (12 mm/min), tube thickness (1.5 mm), fluid pressure (9.6 N/mm2) and die semi-cone angle (20°). The forming characteristics such as thickness distribution (along x and y) and bulged diameter were studied using toolmakers microscope and coordinate measuring machine. Maximum shear thinning is observed in the largest diameter of the bulged portion of the tube.