Accepted Manuscript

Tailor layered tube hydroforming for fabricating tubular parts with dissimilar thickness

Sangwook Han, Youngyun Woo, Taewoo Hwang, Ilyeong Oh, Young Hoon Moon

PII: S0890-6955(18)30627-8
DOI: https://doi.org/10.1016/j.ijmachtools.2018.11.005
Reference: MTM 3386

To appear in: International Journal of Machine Tools and Manufacture

Received Date: 2 October 2018

Revised Date: 27 November 2018
Accepted Date: 29 November 2018

Please cite this article as: S. Han, Y. Woo, T. Hwang, I. Oh, Y.H. Moon, Tailor layered tube hydroforming
for fabricating tubular parts with dissimilar thickness, International Journal of Machine Tools and
Manufacture (2018), doi: https://doi.org/10.1016/j.ijmachtools.2018.11.005.

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 ACCEPTED MANUSCRIPT

Tailor layered tube hydroforming for fabricating tubular parts with

dissimilar thickness

Sangwook Han1, Youngyun Woo1, Taewoo Hwang1, Ilyeong Oh1, Young Hoon Moon1*

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1
School of Mechanical Engineering, Pusan National University, 30 Jangjeon dong,

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Geumjeonggu, Busan 46241, Republic of Korea

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∗ Corresponding author. E-mail address: yhmoon@pusan.ac.kr (Y.H. Moon).

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School of Mechanical Engineering, Pusan National University, 30 Jangjeon dong,
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Geumjeonggu, Busan 609-735, Republic of Korea
M

•Sangwook Han, School of Mechanical Engineering, Pusan National University, 30 Jangjeon dong,
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Geumjeonggu, Busan 46241, Republic of Korea. Email: swhan@pusan.ac.kr

TE

•Youngyun Woo, School of Mechanical Engineering, Pusan National University, 30 Jangjeon dong,
EP

Geumjeonggu, Busan 46241, Republic of Korea. Email: yywoo@pusan.ac.kr

•Taewoo Hwang, School of Mechanical Engineering, Pusan National University, 30 Jangjeon dong,
C

Geumjeonggu, Busan 46241, Republic of Korea. Email: twhwang@pusan.ac.kr

AC

•Ilyeong Oh, School of Mechanical Engineering, Pusan National University, 30 Jangjeon dong,

Geumjeonggu, Busan 46241, Republic of Korea. Email: iyoh@pusan.ac.kr

•Young Hoon Moon, Corresponding author*

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Tailor layered tube hydroforming for fabricating tubular parts with

dissimilar thickness

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C EP
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Abstract
To produce highly functional tubular parts with locally different properties, tailor welded tubes
(TWTs), which are made by tube-to-tube welding of tubes having different thicknesses or mechanical
properties, are hydroformed. Notwithstanding the numerous applications of TWT hydroforming
processes, TWT presents some disadvantages and considerable risk owing to the presence of a weld

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seam. This study proposes and characterizes the tailor layered tube (TLT) hydroforming process,
which can fabricate hollow tubular parts with dissimilar thicknesses by using TLTs without welding.

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The proposed TLT hydroforming process was implemented and characterized both numerically and
experimentally to validate its feasibility. The optimal loading path to prevent defects including

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insufficient bulging and wrinkle were analytically determined and verified by experiments. The
deformation behaviors of TLT were also characterized at various processing parameters. The results

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demonstrate that the proposed TLT hydroforming process can be a feasible alternative for achieving
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tailored properties even with dissimilar thicknesses, with high reliability.
Keywords: hydroforming; tailor layered tube (TLT); tailor welded tube (TWT); loading path; finite
element method (FEM)
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Nomenclature
,
TE

: initial and instantaneous diameters

, : initial and instantaneous tube lengths

EP

: strength coefficient

: strain hardening exponent

C

, : internal and forming pressures

AC

, , : contact pressures generated between inner and center tubes, between center and outer
tubes and between inner and outer tubes

: contracting stroke

, : initial and instantaneous tube wall thicknesses

, : instantaneous two and three-layered tube wall thicknesses

∆ : thickness variations
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, : initial and instantaneous volumes of two-layered tube

, : initial and instantaneous volumes of three-layered tube

, , : volumes of Zone A, Zone B and Zone C

: stress ratio

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: strain ratio

, , : initial, minor and major curvature radii

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, , : hoop, axial and normal stresses

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: equivalent stress

, , : tangential, axial and radial strains

:̅ equivalent strain

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1. Introduction
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Tube hydroforming is a forming process that utilizes pressurized fluid rather than a hard tool to
plastically deform a tubular material into a desired shape. Tube hydroforming positions the tube into
D

the die and then expands it by applying internal pressure on the inside wall of the tube until the tube
TE

conforms to the shape of the die cavity. Simultaneously, because the tube ends are pressed by the
punches in the direction of the tube axis, the excessive thinning of the wall in the expansion areas can
EP

be prevented by the axial feeding effect [1-3]. Compared with conventional die-stamping processes,

tube hydroforming technology can deform metal into complex and variable cross-sectioned tubes with
weight reduction, lower tooling cost, fewer secondary operations, less scrap, and enhanced structural
C

strength and stiffness [4-6]. Major applications of tube hydroforming occur in the automotive, home
AC

appliance, plant pipe installations, and aircraft industries as well as in the manufacturing of structural
components [7, 8].
However, tube hydroforming exhibits certain disadvantages while producing highly functional tubular
parts with locally different properties. Such tailored properties can be achieved by fabricating a tailor
welded tube (TWT), which is fabricated by tube-to-tube welding of tubes having different thicknesses,
coatings, alloys, or mechanical properties [9, 10]. The TWT hydroforming process offers an
opportunity to achieve the advantages of both hydroforming and the popular tailor welded blank
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(TWB) in sheet metal forming [11]. Chu et al. [12] studied the deformation sequence from a thicker to
a thinner tube in order to improve the thickness uniformity of a hydroformed TWT. Chu et al. [13]
also investigated the characteristics of welding seam movement during TWT hydroforming. Liu et al.
[14] investigated the effect of the thickness ratio and length ratio on the deformation behavior of TWT
during a free bulging process, through finite element simulation. Natal Jorge et al. [15] numerically

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studied the relationship between the load paths and displacements during TWT hydroforming by

setting the welding-line heights and thickness ratios as the main process parameters. Notwithstanding

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the numerous applications of TWT hydroforming processes, TWT exhibits potential risk. Merklein et
al. [16] reported that the weld line moves when stress concentration occurs in a TWB, which can

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result in damage to the mold and breakage of the welded portion. This type of problem can occur in
TWT hydroforming also. Moreover, to manufacture TWT having different thicknesses, there is a

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constraint that the outer diameters of the thick tube and the thin tube need to be equal, whereas the
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inner diameters must differ. If the outer diameters of the thick tube and the thin tube are not equal, a
special punch system is required to prevent leakage during internal pressing and axial feeding.
To solve these potential and fundamental problems, the present study proposes alternative
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hydroforming process focusing on a tailor layered tube (TLT). A TLT is a tubular component
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consisting of different tubes, i.e., a combination of two or more tubes with identical or different
materials. A TLT can provide combinations of properties that are challenging to achieve with only one
TE

tube [17-20]. Numerous studies have been carried out in relation to multi-layered tube hydroforming.
Kim et al. [21] proposed discrete layer hydroforming of a three-layered tube, which can selectively
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deform only the outer tube without deforming the inner tubes, by piercing holes in the inner tubes.
The results demonstrate that the proposed process can be applied to hollow forming of non-
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axisymmetric layered tubes for structural purposes. Liu et al. [22] studied the springback of bi-layered
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non-homogeneous bellows in hydroforming through a comparative analysis of single-layered and bi-

layered homogeneous bellows based on FE simulation. Seyedkashi et al. [23] analytically discussed
and experimentally verified the bi-layered hydroforming of copper/aluminum and carbon
steel/stainless steel tubes. Islam et al. [24] simulated the hydroforming of an X-shaped layered tube

consisting of brass and copper tubes and explained the mechanical stresses of the forming products.
Alaswad et al. [25] investigated the effect of geometrical factors on the protrusion height and
thickness reduction in T-shape bi-layered tube hydroforming under a multi-objective optimization

framework, using finite element analysis (FEM) and response surface methodology (RSM).
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Fig. 1 shows a comparison of hydroforming in the conventional TWT and that in the proposed TLT.
As shown in Fig. 1(a), the TWT was manufactured by joining tubes of different thicknesses by
welding. However, the TLT can achieve tailored thickness through a tailored layering of tubes without
using the welding process, as shown in Fig. 1(b). Because welding was not performed in TLT, various
problems caused by the welding seam in TWT can be completely removed.

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This study proposes the TLT hydroforming process, which can fabricate hollow tubular parts with

dissimilar thicknesses by using partially layered tubes. To characterize a TLT hydroforming process,

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two types of TLTs are applied in this study. The optimal load path to prevent defects including
insufficient bulging and wrinkle were analytically determined and verified by experiments. The

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deformation behaviors of two and three-layered zones in TLT exhibiting non-axisymmetric
complicated shape were investigated at various process parameters. The feasibility of the proposed

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TLT was estimated by both numerical and experimental analyses of the formed shape and thickness
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profiles.
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TE
EP

(a)
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(b)
Fig. 1 Schematic drawing of (a) tailor welded tube and (b) proposed tailor layered tube, before and
after hydroforming
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2. Process description of tailor layered tube hydroforming

2.1 Tailor layered tube
Fig. 2 shows a schematic drawing of two types of TLTs. A TLT consists of outer, center, and inner
tubes. The local thickness can be changed by changing the position of the center tube.

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(a)

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(b)
TE

Fig. 2. Schematic drawing of manufacturing of tailor layered tubes through combinations of outer,
center, and inner tubes: (a) Type A and (b) Type B.
EP

As shown in Fig. 2, two types of TLTs are designed based on the location of the center tube: (a)
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Type A: three/two-layered tube (thick part/thin part) and (b) Type B: three/two/three-layered tube
(thick part/thin part/thick part). Fig. 3 shows the geometry of the internal surface in the forming die
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and the target forming shape. It is a non-axisymmetric shape with round and angular shapes.
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Fig. 3. Forming dimension
Table 1 lists the dimensions of the tubes used for the experiments. The material used for the outer,

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center, and inner tubes was AISI 304 stainless steel. Table 2 presents the tensile properties of the tubes
tested.
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Table 1 Dimensions of tubes.
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Tube Outer tube Center tube Inner tube

Inner diameter, mm 60.5 58.3 55.3

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Outer diameter, mm 63.5 60.5 58.3

TE

Thickness, mm 1.5 1.1 1.5

Length, mm 240 120 (Type A), 85 (Type B) 240
EP

Table 2 Tensile properties of AISI 304 stainless steel.

C

Yield stress, MPa 349.0

Tensile stress, MPa 1171.3
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Elongation, % 45.3
Young’s modulus, GPa 193
Poisson’s ratio 0.29
Density, kg/m3 8,000
Strength coefficient (K), MPa 1611
Strain hardening exponent (n) 0.44
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2.2 Tailor layered tube hydroforming

Fig. 4 shows a schematic drawing of the TLT hydroforming process. The TLT is placed in the space
between the dies, and both ends of the TLT are completely sealed by the left and right punches. As the
hydraulic pressure increases, the tube in the forming zone gradually deforms. Finally, the tube is
formed into the desired die shape with the non-axisymmetric complicated part.

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Fig. 4. Tailor layered tube hydroforming process
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In general, the deformation during the hydroforming process can be classified into two main zones:
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the forming zone and the feeding zone. The forming zone is a space formed according to the inner
shape of the die. When pressure is applied inside the tube, the tube gradually deforms to the desired
D

shape. In the feeding zone, the tube is in complete contact with the die without noticeable deformation,
TE

and the material flow proceeds to the forming zone by the punches. The material flow is facilitated
toward the forming zone, thereby increasing the formability. For Type A, there is an empty space
EP

between the inner and outer tubes at the end of the two-layered tube. This reduces the contact force
between the end of the two-layered tube and the punch owing to the expansion at the end of the inner
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tube during the hydroforming process. Eventually, the forming zone is insufficiently formed owing to
hydraulic leakage. Thus, the end of the two-layered tube in the feeding zone was filled by inserting a
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spare tube between the outer and inner tubes.

2.3 Finite element modeling for tailor layered tube hydroforming

For the FE simulation of TLT hydroforming process, the commercially available ABAQUS
software with explicit dynamic solver was used. The FE simulation model consists of the die, punches,
and tubes, as shown in Fig. 5. In the FE simulation, only half the geometry is modeled considering the
symmetry of the profile in the z-axis direction. The die and punch were assumed to be rigid bodies,
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and three-dimensional (3D) models were used. The inner, center, and outer tubes were separately
modeled using S4R deformable shell elements with five integration points. The mesh size of the tubes
was 2 × 2 mm. Moreover, the tubes were assumed to be isotropically hardened with elastic–plastic
material. The Coulomb coefficient of friction between the die and tube was assumed to be
approximately 0.05. The FE simulation was performed with four cases: Type A TLT, Type B TLT,

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two-layered tube, and three-layered tube. The internal pressure in the FE simulation was linearly

increased until the TLT was completely filled in the die cavity.

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Fig. 5. Finite element simulation mesh model

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3. Determination of loading path for tailor layered tube hydroforming

EP

The loading path is an important process parameter to achieve high quality of final product from
the hydroforming process [26]. To determine the loading paths for the TLT hydroforming, analytical
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forming pressures were used in this study.

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Fig. 6. Stresses acting on an element at pole dome [27].

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Because the thickness of the thin-walled tube is significantly smaller than the external diameter, the
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normal stress σ3 is considered negligible compared to the hoop σ1 and axial σ2 stresses. As shown in
Fig. 6, for the stress state of the element at the pole dome under internal pressure Pi, the equilibrium
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equation can be ordinarily expressed as

"# " ()
$#
+ $& = (1)
& )
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The stress ratio α and strain ratio β are defined as

TE

" *
= "&, = +& (2)
# #
EP

The principal strains (tangential ε1, axial ε2, and radial ε3 strains) can be denoted as
$ /
= ln $# , = ln /# = , = ln )
= −(1 + ) (3)
. . .
C

where ρ0 and ρ1 are the initial and instantaneous curvatures, respectively; l0 and l1 are the initial and
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instantaneous tube lengths respectively; and t0 and ti are the initial and instantaneous wall thicknesses,
respectively. According to the Levy–Mises flow rule, the stress and strain ratios are related as follows:
56 78
α= , = (4)
65 87

The von Mises yield criterion (plane stress) and its equivalent strain can be expressed as
= 9√1 − + ; (5)

<̅ = =>1 + + ? (6)

√
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Combining Eqs. (1), (2), and (5), the internal pressure is

@
" A
= = + ? (7)
√ 8A6A & $# $&

3.1 Calculation of forming pressure

The TLT consists of inner, center and outer tubes, which are divided into two and three-layered

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zones. To determine the forming pressure during free bulging, the structural specificity of the TLT
should be considered. N. Asnafi [28] and B. A. Sreenivasulu et al. [29] proposed the analytical model

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to predict the forming pressure of single tube during free bulging. Based on the forming pressure
model of a single tube, Seyedkashi et al. [23] and Xu et al. [30] proposed models to predict the

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forming pressure of multi-layered tubes. In this study, an analytical model to characterize TLT
hydroforming process has been developed.
Fig. 7 shows the pressure conditions of the individual tubes in the TLT. For the three-layered zone,

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Pf is applied to the internal wall of the inner tube as shown in Fig. 7(a). When the inner tube begins to
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expand, a contact pressure Pic is generated between the center and inner tubes, and simultaneously, Pco
is generated between the center and outer tubes. The actual pressures of the outer, center, and inner
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tubes are expressed as Pco, Pic - Pco, and Pf - Pic, respectively. For the two-layered zone, Pf is applied to
the internal wall of the inner tube as shown in Fig. 7(b). When the inner tube starts to expand and
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comes in contact with the outer tube, a contact pressure Pio is generated between the outer and inner
TE

tubes. The actual pressures of the outer and inner tubes are expressed as Pio and Pf - Pio, respectively.
C EP
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(a)
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(b)
Fig. 7. Pressure conditions for hydroforming: (a) three-layered zone and (b) two-layered zone

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The tubes were assumed to be plastically deformed into a cylindrical shape during free bulging.

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This assumption implies that ρ2 = ∞. With this assumption, Eq. (7) can be re-expressed as
@
"
= ∙ )
(8)
√ 8A6A & $#
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Assuming that the tube material obeys the Ludwik–Hollomon hardening relationship,
= ( )̅ C (9)
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For the outer tube, the instantaneous radius is

9D)E 8 )E ;
=
D

(10)
TE

Combining Eqs. (6) and (9) with Eqs. (8) and (10) yields
CE
E E E JE
) I (+# ) M
= GH = KL N1 + +( ) OP (11)
9D)E 8 E
) ;> 8A 6(A )
E E &
EP

According to Eqs. (10) and (3)

$E DE 8 E
= ln =$#E ? = ln =D)E 8 )E ?
C

(12)
. . .
AC

Substituting Eqs. (12) and (4) into Eq. (11), another form of the final equation for the internal
pressure in the plastic deformation of the outer tube is obtained
CE CE 8 CE 8
D)E 8 )E
= GH =2 RDE 8 E S = 8A E
? =>1 − +( ) ? = D.E 8 .E
? (13)
) )

For the center tube, the instantaneous radius is

9D)T 8 )T ;
= (14)

Combining Eqs. (6) and (9) with Eqs. (8) and (14) yields
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CT
T T T JT
) I (+# ) M
= − = KL N1 + +( ) OP (15)
9D)T 8 T
) ;> 8A 6(A )
T T &

According to Eqs. (14) and (3),

$T D)T 8 )T
= ln = #T ? = ln = ?
D.T 8 .T
(16)
$.

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Substituting Eqs. (16) and (4) into Eq. (15), another form of the final equation for the internal
pressure in the plastic deformation of the center tube is obtained:
CT CT 8 CT 8
D)T 8 )T
= − =2 RDT 8 T S = ? =>1 − +( ) ? = ?

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D.T 8 .T
(17)
) ) 8AT

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For the inner tube, the instantaneous radius is
=D)) 8 )) ?
= (18)

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Combining Eqs. (6) and (9) with Eqs. (8) and (18) yields
) C)
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) ) ) J
) I 9+# ; M
= −( GH )= KL N1 + + ( ) OP (19)
&
9D)) 8 )) ;L 8A) 69A) ;
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According to Eqs. (18) and (3),

$) D)) 8 ))
= ln R #) S = ln R S
D.) 8 .)
(20)
$.
D
TE

Substituting Eqs. (20) and (4) into Eq. (19), another form of the final equation for the internal
pressure in the plastic deformation of the inner tube is obtained:
C) C) 8 C) 8
D)) 8 ))
= −( GH )=2 R )S = ? =>1 − +( ) ? R S
EP

D)) 8 ) D.) 8 .)
(21)
8A)

To calculate tii, tci, and toi, it is assumed that ε1 + ε 2 + ε3 = 0. Therefore, combining Eq. (3) with Eqs.
C

(10), (14), and (18),

89 65) ; 89 65) ; 89 65) ;
AC

D)) DT DE
≅ R )S , ≅ =D)T ? , ≅ =D)E ? (22)
DE E E

The instantaneous thickness of the two-layered tube is

89 65) ; 89 65) ;
D)) DE
= R )S + =D)E ? (23)
DE E

The instantaneous thickness of the three-layered tube is

89 65) ; 89 65) ; 89 65) ;
D)) DT DE
= R )S + =D)T ? + =D)E ? (24)
DE E E
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For the two-layered tube, the forming pressure can be calculated by combining Eq. (13) with Eq.
(21):
=

C) C) 8 C) 8
D)) 8 ))
2 R S = )? =>1 − +( ) ? R S +
D)) 8 )) 8A D.) 8 .)

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CE CE 8 CE 8
D)E 8 )E
2 R S = E? =>1 − +( ) ? = ?
D)E 8 )E D.E 8 .E
(25)
8A

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For the three-layered tube, combining Eq. (13) with Eq. (17),
=

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CT CT 8 CT 8
D)T 8 )T
2 R S = T? =>1 − +( ) ? = ? +
D)T 8 )T 8A D.T 8 .T

CE CE 8 CE 8
D)E 8 )E
2 RDE 8 E S = ? =>1 − +( ) ? = ?

U D.E 8 .E
8A E
(26)
) )
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Combining Eq. (26) with Eq. (21), the forming pressure can be calculated as
=
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C) C) 8 C) 8
D)) 8 ))
2 R S = 8A) ? =>1 − +( ) ? R S +
D)) 8 )) D.) 8 .)
D

CT CT 8 CT 8
D)T 8 )T
2 RD T 8 T S = 8A T
? =>1 − +( ) ? = D.T 8 .T
? +
TE

) )

CE CE 8 CE 8
D)E 8 )E
2 RDE 8 E S = ? =>1 − +( ) ? = ?
D.E 8 .E
(27)
) ) 8A E
C EP

3.2 Loading path for TLT hydroforming

Fig. 8 shows the predicted forming pressure and thickness with respect to the stress ratio, using Eqs.
AC

(23), (24), (25) and (27). As the stress ratio increases from -1 to 1, the thickness of the two and three-
layered tube gradually decrease, but the forming pressure shows a different tendency with respect to
the stress ratio. For both the two and three-layered tubes, the minimum forming pressure was obtained
in the pure shear state (α = -1), whereas the maximum forming pressure was required in the plane
strain state (α = 0.5). Comparisons of the forming pressures and thicknesses of the two and three-
layered tubes illustrate that the three-layered tube requires higher forming pressure and shows a larger
thickness compared to the two-layered tube. In actual hydroforming, the stress ratio α lies in the range
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0.5 < α < 1 [23]. Therefore, the average pressure between α = 0.5 and α = 1 was considered as the
maximum load immediately before the tube came into contact with the die, i.e., in the free bulging
stage. In this study, 63.6 MPa and 87.1 MPa were set to be the forming loads of the two-layered and
three-layered tubes, respectively.

140 7

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2-layered tube 3-layered tube
120 6

Predicted thickness, m m
Thickness
Forming pressure, MPa

Forming pressure

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100 5

80 4

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60 3

40 2

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Plane strain
20 1
Pure shear Uniaxial tension Biaxial tension
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0 0
-1.0 -0.5 0.0 0.5 1.0
Stress ratio, α
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Fig. 8. Variations of predicted forming pressure and thickness at various stress ratios
D

To obtain the approximate axial feeding to prevent leakage during hydroforming, the contracting
TE

movements during hydroforming without axial feeding were estimated. The contracting movements of
both the tube ends during hydroforming, S1 and S2, are shown in Fig. 9. The total contracting stroke S
EP

was obtained by Eq. (28):

= + (28)
C
AC

If the axial feeding is less than S, a separation can be created between the end of the tube and the

punch, which implies the likelihood of hydraulic leakage. Therefore, the axial feeding needs to exceed
the total contracting stroke S.
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Fig. 9. Contracting strokes during hydroforming without axial feeding
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The contracting movements of both ends of the two-layered tube were analytically obtained as
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shown in Fig. 10.

D
TE
C EP
AC

Fig. 10. Schematic drawing to determine the contracting strokes of the two-layered tube

Considering the symmetry of the left and right sides of the two-layered tube, the initial volume
V0two of the two-layered tube is calculated as
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= V(2W + 2W + W ) X= − ?+( − )Y (29)

The instantaneous volume Vitwo of the two-layered tube is denoted as

= Z + [ + \ (30)

where VA, VB and VC are volumes of zone A, zone B, and zone C, respectively.

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The volume of zone A can be obtained as

= 2V(W − ) X= − ?+( − )Y

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Z (31)

The volume of zone C can be obtained as

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\ = VW X= − ?+9 − ;Y (32)

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The volume of zone B can be obtained as
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[ = 2V X (] − ^ )W + (]_ − ^`)W + (_ − ` )W Y (33)

where
M

D)E 8D.E D.E (D)) 8 )) )8(DE) 8 E)) D.)

]= , _= , ^= , `= − (34)
ab ab
D

As the initial and instantaneous volumes of the two-layered tube are equal from the principle of
TE

volume constancy.

= (35)
EP

The contracting stroke S of the two-layered tube can be obtained by

& & #
ac =D)) )) 8 )) ?6=D)E )E 8 )E ? 9g & 8 & ;ab f 6(gh8 )ab & 69h& 8 & ;ab
= Kd )&
e − 1P + Kf & P−W (36)
C

=D.) .) 8 E E E& =D.) .) 8 ) E E E&

. ?6(D. . 8 . ) . ?6(D. . 8 . )
AC
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Fig. 11. Schematic drawing to determine the contracting strokes of the three-layered tube

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The contracting movements of both ends of the three-layered tube were analyzed as shown Fig. 11.
Considering the symmetry of the left and right sides of the two-layered tube, the initial volume V0three
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of the three-layered tube is calculated as

= V(2W + 2W + W ) X= − ?+9 − ;+( − )Y (37)

D
TE

The instantaneous volume Vithree of the three-layered tube is denoted as

= Z + [ + \ (38)
EP

where VA, VB and VC are volume of zone A, zone B, zone C, respectively.

The volume of zone A can be obtained as

C

Z = 2V(W − ) X= − ?+9 − ;+( − )Y

AC

(39)

The volume of zone C can be obtained as

\ = VW X= − ?+9 − ;+9 − ;Y (40)

The volume of zone B can be obtained as

[ = 2V X (] − i )W + (]_ − iℎ)W + (_ − ℎ )W Y (41)

where
 ACCEPTED MANUSCRIPT

D)E 8D.E D.E (D)) 8 )) )8(DE) 8 E) ) D.)

]= , _= , i= , ℎ= − (42)
ab ab

As the initial and instantaneous volumes of the three-layered tube are equal from the principle of
volume constancy.

= (43)

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The contracting stroke S of the three-layered tube can be obtained by
& & & #
ac =D)) )) 8 )) ?6=D)T )T 8 )T ?6=D)E )E 8 )E ? 9g & 8 & ;ab f 6(gh8 )ab & 69h& 8 & ;ab
= Kd e − 1P + Kf P−W

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)& &
T& E& E&
(44)
=D.) .) 8 T T E E
. ?6=D. . 8 . ?6(D. . 8 . ) =D.) .) 8 ) E E
. ?6(D. . 8 . )

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As the thickness reduction is decreased as stress ratio approaches to α = -1, the upper limit of

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contracting strokes can be obtained at α = -1. Table 3 shows the contracting strokes calculated at α = -
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1, -0.5 and 0.
M

Table 3 Contracting strokes obtained by analytic model.

Stress ratio α Two-layered tube S, mm Three-layered tube S, mm

D

-1 13.18 9.28
TE

-0.5 11.20 7.50

0.0 8.33 4.88

EP

As the contracting stroke has a sensitive variation with α, it is hard to determine the exact S value.
C

As the instantaneous thickness variations can be more precisely simulated by FEM, the contracting
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strokes obtained by FE simulation have been used in determining loading path for TLT hydroforming.

To estimate the axial feeding to prevent leakage during hydroforming, the FE simulation was
performed by applying an internal pressure without axial feeding

Fig. 12 shows the two and three-layered tubes used in the FE simulation of the TLT. As a TLT has
both two and three-layered zones, the forming pressure of the TLT is assumed to be the mean forming
pressure of the two and three-layered tubes. Therefore, the FE simulation was performed at 75.3 MPa,
which is the mean of 63.6 MPa and 87.1 MPa. To obtain the reference values for the axial feeding, the
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FE simulation was performed by applying internal pressure without axial feeding. Table 4 lists the
values of S1, S2, and S obtained from the FE simulations when the free bulging is performed at 75.3
MPa.

PT
RI
U SC
AN
(a) (b)

Fig. 12. Tubes used in FE simulations of the TLT hydroforming: (a) two-layered tube and (b) three-
M

layered tube
D

Table 4 Simulation results of hydroforming without axial feeding

TE

Tube S1, mm S2, mm S, mm

Two-layered tube 5.24 5.23 10.47
EP

Three-layered tube 3.24 3.22 6.46

C

When the results of Fig. 8 and Table 4 are combined, the loading path can be determined as shown
AC

in Fig. 13. Path-3L and Path-2L are the loading paths for the three-layered tube and two-layered tube,
respectively. As a TLT has both two and three-layered zones, the loading path of the TLT is set to lie
between those of the two and three-layered tubes. The values of the total contracting stroke S based on
the simulation results in Table 4 were used as the reference values for the axial feeding. To improve
the shape accuracy of the formed product without process-induced defects, a calibration pressure of
up to 170 MPa is applied after the free bulging stage.
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160

LT
rT
fo

Calibration
140

Calibration
th
Internal pressure, MPa

3L

pa
th -
120

g
in
Pa

ad

L
-2
Lo
100

th
Pa
87.1
80 75.3
63.6

PT
60

Free bulging

Free bulging
40

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20 3-layered 2-layered
tube tube
0
0 5 10 15 20 25 30 35

SC
Axial feed, mm

Fig. 13. Loading path for tailor-layered tube hydroforming

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AN
Fig. 14 schematically shows the deformation behaviors at the free bulging stage when the
hydroforming is performed without axial feeding. In both the Type A and Type B TLTs, the two-
layered zone first comes into contact with the internal wall of the die, and the free bulging is
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completed. At this time, the three-layered zone is still undergoing the free bulging. As the pressure is
increased, the calibration of the two-layered zone progresses; moreover, the three-layered zone also
D

comes into contact with the internal wall of the die, and the free bulging is completed.
TE
C EP
AC

(a)
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PT
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SC
(b)

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Fig. 14. Deformation behaviors of tailor-layered tube in free bulging stage: (a) Type A and (b) Type
B
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To demonstrate the effects of the selected optimal load path, the TLT hydroforming experiments
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were performed along Path-3L and Path-2L; these are the loading paths for the three-layered and two-
layered tubes, respectively.
D

Fig. 15 shows the hydroformed shapes obtained at Path-3L and Path-2L. When the loading path
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followed Path-3L, hydraulic leaks occurred before the process was completed; moreover, the three-
layered zone was negligibly bulged compared to the two-layered zone. Consequently, both the Type A
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and Type B TLTs exhibited insufficiently bulged shapes. In contrast, in Path-2L, wrinkles were
observed in the two-layered zone near the boundary line between the three and two-layered zones.
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This implies that although the axial feeds are equally applied to the ends of the Type A and Type B
TLTs, higher strain was concentrated in the two-layered zone with the lesser thickness than the three-
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layered zone with the larger thickness. Therefore, in Path-2L, the wrinkles were generated in the two-
layered zone owing to excessive axial feed as the calibration stage progressed. The experimental
results for Path-3L and Path-2L reasonably indicate that the optimal load path should lie between
Path-3L and Path-2L.
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Three-layered
zone
Three-layered
zone

PT
Two-layered
zone

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Two-layered
zone Three-layered
zone

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Type A Type B

U (a)
AN
M
D
TE
C EP
AC

(b)
Fig. 15. Final shapes of tailor layered tube according to the loading paths: (a) Path-3L and (b) Path-
2L

4. Finite element simulation of tailor layered hydroforming

The FE simulation of the TLT hydroforming process based on loading path shown in Fig. 13 was
performed. Fig. 16 shows the simulated equivalent plastic strain distribution to characterize the
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deformation behaviors of TLT during hydroforming. In the case of Type A, plastic deformation first
occurs in the two-layered zone located on the right side. As the pressure increases, the equivalent
plastic strain in the two-layered zone is also increased. Thereafter, the plastic deformation is
propagated to the three-layered zone through the boundary line between the three and two-layered
zones. For Type B, the plastic deformation starts at the center zone and then gradually spreads as the

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pressure increases.

Three-layered Two-layered Three-layered

Three-layered zone Two-layered zone

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zone zone zone

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P=34MPa

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P=51MPa
M
D

P=68MPa
TE

Round

Angle

P=170MPa
EP

(a) (b)
Fig. 16. Equivalent plastic strain distribution during hydroforming of TLT: (a) Type A and (b) Type
C

B
AC

The equivalent plastic strains for both the types of TLT were analyzed based on the region of the
angular shape as shown in Fig. 17. From the inner tube to the outer tube, the strain in the Type A TLT
decreased from 0.276 to 0.239 for the three-layered zone and 0.31 to 261 for the two-layered zone. A
comparison of the equivalent plastic strains of the inner and outer tubes reveals that the deformation
of the two-layered zone was larger than that of the three-layered zone even for the same tube owing to
the differences in the deformation sequences. The two-layered zone is directly deformed from the
inner tube to the outer tube. However, because the three-layered zone is sequentially deformed in the
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order of the inner, center, and outer tubes, the two-layered zone with the lesser deformation exhibits
higher strain than the three-layered zone. In the Type B TLT, the position of the two and three-layered
zones are different. However, the tendency of the equivalent plastic strains in it is similar to that of the
Type A TLT.

PT
RI
U SC
AN
M

(a)
D

Outer tube
TE

Center tube1
EP

Inner tube 0.251

0.251
0.238
0.238
C

0.251
AC

0.301
0.301 Center tube2
0.291
0.291

(b)

Fig. 17. Equivalent plastic strain distributions in hydroformed TLTs: (a) Type A and (b) Type B
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Fig. 18 shows the simulated thickness distributions of the TLT. To analyze the thickness variations,
the thickness in the deformation zone were analyzed in the longitudinal and transverse directions, as
shown in Fig. 19. For the precise analysis of the respective thickness variations of the inner, center,
outer tubes, the thinning ratios were compared. The thinning ratio was calculated by Eq. (45).

∆
Thinning ratio =

PT
(45)
.

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where ∆t and t0 are the thickness variations and the initial thicknesses of inner, center, outer tubes,

respectively. Based on Eq. (45), the total thinning ratio was calculated by the ratio of the total

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thickness variation ∆t(i+c+o) to the total initial thickness t0(i+c+o), i.e., ∆t(i+c+o)/ t0(i+c+o) in the inner, center,
and outer tubes.

U
AN
M
D
TE
C EP
AC

(a)
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PT
RI
U SC
AN
(b)
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Fig. 18. Thickness variations in hydroformed TLTs: (a) Type A and (b) Type B
D
TE
C EP
AC

(a)
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PT
(b)

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Fig. 19. Measuring-direction of thickness: (a) longitudinal direction and (b) transverse direction.

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Fig. 20 shows the thickness distributions of the TLT in the longitudinal direction. In both the Type
A and B TLTs, the thinning ratio of the inner tube was the highest, and it decreased from the center

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tube to the outer tube. However, the thickness distributions in the three and two-layered zones
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exhibited significant differences. In the case of the Type A TLT, the inner tube in the three-layered
zone was approximately 10.7%, whereas that in the two-layered zone was increased to approximately
12.2%. In the outer tube, the three-layered zone was approximately 8.7%, whereas the two-layered
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zone was decreased to approximately 6.5%. In the same segment, the difference in the thinning ratio
between the inner and outer tubes in the three-layered tube was approximately 2%, whereas that of the
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two-layered tube was approximately 6%. Although the thickness distributions of the individual tubes
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are different, the maximum and minimum are approximately 9.8% and 9.2%, respectively, in terms of
the total thinning ratio. The difference between the maximum and minimum total thinning ratios is
EP

0.6%. The Type B TLT having different locations of the three and two-layered zones exhibits
thickness variations similar to those of the Type A TLT.
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AC
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25
Outer tube
Center tube
20 Inner tube
Total thinning ratio

Thinning ratio, %
15

PT
10

RI
0
0 20 40 60 80 100 120

SC
Distance, mm

(a)
25
U
AN
Outer tube
Center tube1
20 Center tube2
Inner tube
Thinning ratio, %

Total thinning ratio

15
D

10
TE

0
EP

0 20 40 60 80 100 120
Distance, mm
C

(b)
AC

Fig. 20. Thickness distribution in longitudinal direction: (a) Type A and (b) Type B

Fig. 21 shows the thickness distributions of the TLT in the transverse direction. In both the Type A
and B TLTs, the variations in the total thinning ratios in the three and two-layered zones were similar,
although there were certain differences in the thinning ratio among the individual tubes.
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30
3-layered 2-layered
Outer tube
25
Center tube

Thinning ratio, %
Inner tube
20 Total tinning ratio

PT
15

10

RI
5
a b c d e f

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Measured point
(a)

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30
3-layered 2-layered
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Outer tube
25
Center tube
Thinning ratio, %

Inner tube
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20 Total tinning ratio

15
D
TE

10

5
a b c d e f
EP

Measured point
(b)
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Fig. 21. Thickness distribution in transverse direction: (a) Type A and (b) Type B
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To predict the critical points in which necking instability and fracture may occur during the TLT
hydroforming process, a damage initiation criterion is incorporated in the model. The forming limit

diagram (FLD) proposed by Naghibi et al. [31] was used as the failure criterion for investigating
formability of the 304 stainless steel. To predict failure, the forming limit diagram damage initiation
criterion(FLDCRT) was used as shown in Fig. 22. If an element of the tube has a maximum value of
FLDCRT criterion equal to or greater than 1, tearing would occur [32]. As can be seen in the figure,
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the maximum value of FLDCRT tended to decrease from the inner tube to the outer tube in both type
A and B. Since the maximum value of all tubes at all locations is less than 1, defects related to
damage evolution do not occur in the TLTs.

PT
RI
U SC
AN
M

(a)
D
TE
C EP
AC

(b)
Fig. 22 Estimation of damage evolution based on FLDCRT: (a) Type A and (b) Type B
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5. Experimental validation
To validate the proposed TLT hydroforming process, experiments were performed with the tube
hydroforming system shown in Fig. 23. The tube hydroforming system can apply a pre-programmed
path to regulate the axial feeding, vertical hydraulic cylinder, and internal pressure. The axial feeding
consists of two 80-ton actuators mounted horizontally at both ends of the tube to prevent hydraulic

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leaks. The vertical hydraulic cylinder capable of delivering up to 100 tons of clamping force provides
up-and-down movement of the upper die. The internal hydraulic pressure is regulated by the pressure

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intensifier unit, and the maximum pressure capacity of the hydraulic fluid is 200 MPa.
When the response is slow or there is an intermittent pressure drop, the system continues

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hydroforming after stopping the end-feed actuator from advancing, until the hydraulic pressure attains
the required level. If the hydraulic pressure does not attain the required level of pressure continuously,

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the process automatically terminates.
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M
D
TE
C EP
AC

Fig. 23. Tube hydroforming system

Fig. 24 shows the hydroformed shapes of the Type A and Type B TLTs using the optimal loading
path shown in Fig. 13. As shown in the figure, both the TLTs were successfully formed without
process-induced defects.
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Round
Angular

Three-layered
Three-layered Two-layered
zone
zone zone

PT
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Two-layered
zone

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(a)

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AN
M
D
TE
C EP

(b)
AC

Fig. 24. Hydroformed part obtained by optimal loading path: (a) Type A and (b) Type B

Fig. 25 shows the longitudinal section profiles of hydroformed TLTs. Both the TLTs exhibit
remarkable filling in the die cavity without shape defects.
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Fig. 25. Longitudinal section profiles of hydroformed TLTs: (a) Type A and (b) Type B

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Fig. 26 shows the thickness variations of the Type A and Type B TLTs. The thickness variation
obtained by FE simulation showed good agreement with the experimentally obtained thickness
variation. The average thickness of the Type A TLT was approximately 3.65 mm and 2.64 mm for the

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three and two-layered zones, respectively. The thickness distribution of the Type B TLT was 3.66 mm
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and 2.61 mm for the three and two-layered zones, respectively. From the perspective of the thinning
ratio, the difference between the three and two-layered zones was approximately 1.02% and 2.26% for
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Type A and Type B, respectively. The thickness variations shown in the figure indicate that the
thickness can be selectively and conveniently regulated through the tailored combination of the tubes.
D
TE

5.5

5.0 EXP FEM

Type A
EP

4.5 Type B
Thickness, m m

4.0
C

3.5
AC

3.0

2.5

0 10 20 30 40 50 60 70 80
Distance, mm
Fig. 26. Thickness variations of Type A and Type B TLTs.

As described above, the results of the investigation verify that the proposed TLT hydroforming can
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manufacture complicated hollow products with tailored thicknesses with high precision and
convenience and reduced manufacturing cost. The proposed TLT can be a feasible alternative for
solving the potential and fundamental problems of TWT.

6. Conclusions

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This study proposes and characterizes the TLT hydroforming process, and the following

conclusions were obtained:

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1) The proposed TLT hydroforming process can be a feasible alternative for achieving tailored

SC
properties with dissimilar thicknesses, without tube welding process, unlike the TWT hydroforming
process.

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2) The thickness variations of the three/two and three/two/three-layered tubes verify that the thickness
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profile can be selectively and conveniently regulated through the tailored combination of tubes.
3) Through the analytical and numerical analysis, a method to determine the optimal loading path for
a TLT was recommended to prevent insufficient bulging and wrinkle.
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4) With internal pressing, the deformation starts in the two-layered zone and then gradually
D

propagates to the three-layered zone. The deformation sequences significantly change the plastic
strains in the two-layered and three-layered zones.
TE

5) Although the thickness thinning ratio of individual tubes was different, the difference in the total
thinning ratio between the two and three-layered tubes was approximately 0.6–0.8% and fairly
EP

uniform.
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Declaration of Conflicting Interests

AC

The authors declare that there is no conflict of interest.

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Acknowledgement
This work was supported by the National Research Foundation of Korea (NRF) grant funded by the
Korean government (MSIP) (no. 2012R1A5A1048294).

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Highlights:

• Fabricate part with dissimilar thicknesses by tailor layered tube hydroforming

• Selectively regulate thickness profile through the tailored combination of tubes

• Overcome drawbacks owing to the presence of a weld seam in tailor welded tubes

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• Deformation sequences change the plastic strains in the tailor layered zones

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