Community Research and Development Information Service - CORDIS


Final report on Contract no. 7210-PR/051, 1 July 1997 to 31 December 2000

Hydroforming facilitates the production of lightweight components offering the advantage of material savings resulting in reduced weight, improved fuel efficiency and less emissions. The objectives of this research programme are to develop an understanding of the hydroforming process and to illustrate the technical attributes of hydroformed tubes. Also, the weight-saving potential was determined.

The first part of the research was the hydroforming of the tubular component, and the second part was the in-service performance of that component. Experiments and numerical simulations were performed, and a traditional top hat structure was used as a reference. In the hydroforming part, the tests performed were the free expansion of tubes and the forming of a T-shape. The in-service performance tests covered bending and torsion stiffness, side and axial impact, and torsion fatigue.

The hydroformed component performs better in the in-service performance test when the deformations come I the plastic region. This is mainly caused by the increased strain hardening during the hydroforming process and the continuous joint of the component. By using the increased performance, it is possible to construct lighter components. Also, the numerical simulations of the hydroforming process followed by the in-service performance test are a useful and reliable tool to understand and predict the performance of the component.

Additional information

Authors: CARLEER B D, Corus, IJmuiden (NL);LABELLARTE A, CSM, Rome (IT);GUTIERREZ M A, Labein, Bilbao (ES);VELTMANS P, TNO, Eindhoven (NL)
Bibliographic Reference: EUR 20321 EN (2002), pp.67. Euro: 10.00
Availability: EUR-OP reference: KI-NA-20321-EN-S Available from EUR-OP sales agents. URL:
ISBN: ISBN: 92-894-3668-9
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