An Experimental Study on Robustness and Process Capability of the Warm Hydroforming Process

The warm sheet hydroforming process was investigated to determine the optimal process conditions of temperature, pressure, and pressurization rate for maximum formability of AA5754-O using an experimental stretch forming die shape. The optimal process conditions were evaluated to determine the robustness and process capability based on physical measurement of formed parts including thickness strain, cavity fill ratio, and radius of curvature. For the simple die shape investigated, a temperature of $268°C$⁠, a pressure of 25 MPa, and a pressurization rate of 0.22 MPa/s provided the most balanced combination of uniform thickness strain with the greatest cavity fill ratio and sharpest radius. Temperature had a greater effect on measured properties than either pressure or pressurization rate, although the effect of pressure increased as temperature decreased. The procedures demonstrated in this experimental study could be used to optimize process parameters for robust operation of production applications for more complex automotive body panels fabricated by the warm hydroforming process.