Tube-hydroforming experiments on an Al 7003 extruded tube

Tube hydroforming (THF) is a valid alternative technique for the production of parts with enhanced performance in terms of resistance and feasibility of complex shapes. The present paper shows the results of the first tests conducted at the Brescia University Laboratory where experimental equipment, able to run THF experiments, is available. This equipment can be used to conduct experiments to validate the correct process parameters derived from simulations in order to obtain defect-free components and to realize pre-series parts. In particular, in the present research, the feasibility of forming a motorbike suspension arm, obtained from an Al 7003 extruded tube, was analyzed. The experimental thinning values were compared to the simulation ones in order to validate the FE model of the process. The good agreement obtained confirms that FE analysis is a valid tool for virtual prototyping of new processes such as THF.