Research Article Open Access

Analytical and Numerical Analysis of Free Bulge Tube Hydroforming

F. Djavanroodi, M. Gheisary and H. Zoghi-shal


Free bulge hydroforming simulation was analysied to investigate the biaxial behavior of extruded aluminum tubes. A finite element model was constructed to simulate the hydroforming process and asses the influence of friction between die walls and tube, tube material properties and springback of formed tube. It was found that material hardening coefficient had the most significant influence on formability characteristics during bulge hydroforming, the simulated model also revealed that die radius and tube thickness had great effects on springback and hence changed tolerances of formed tube. Also an analytical model for free bulge forming was proposed and it was shown that for β = 0.5(β -ε21), good correlation between experimental and analytical model was obtained. It was also shown that for β = (-1), formability of tube increased and lower pressure is needed for forming the tube.

American Journal of Applied Sciences
Volume 5 No. 8, 2008, 972-979


Submitted On: 25 November 2007 Published On: 31 August 2008

How to Cite: Djavanroodi, F., Gheisary, M. & Zoghi-shal, H. (2008). Analytical and Numerical Analysis of Free Bulge Tube Hydroforming. American Journal of Applied Sciences, 5(8), 972-979.

  • 4 Citations



  • Free bulge forming
  • tube hydroforming
  • friction coefficient
  • strain hardening