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Center for Manufacturing and Design with Lightweight Materials Michigan Technological University 1 Hydroforming of Aluminum Extrusions Background Hydroforming is a manufacturing process where liquid pressure is used to form complex shapes Rolled sheet steels and extruded parts are used to form complex parts using hydroforming Advantages include weight reduction due to part consolidation, reduced investment in tooling, and reduced number and complexity in production steps Faculty: Ghatu Subhash Students: Adam Loukus and Mehdi Imaninejad Research Objective Optimize the process parameters (e.g., axial feed rate and internal pressure path) to obtain maximum formability in aluminum extrusions Identify the influence of extrusion welds on mechanical behavior Development forming limit diagrams Finite element analysis to identify the interplay between process parameter selection and material behavior
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Center for Manufacturing and Design with Lightweight Materials Michigan Technological University 2 Experimental Details and Modeling
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Center for Manufacturing and Design with Lightweight Materials Michigan Technological University 3 Weld Characterization Seam Weld Tensile Specimen 90 degrees0 degrees
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