Determination of optimal loading profiles in warm hydroforming of lightweight materials

Ho Choi, Muammer Koç, Jun Ni

Research output: Contribution to journalArticle

42 Citations (Scopus)


In this study, a methodology is developed to determine proper profiles of the hydraulic pressure and the blank holder force under warm hydroforming conditions at different punch speeds. First, finite element models (2-D and 3-D) are developed and validated through comparisons with the experimental results from the literature. To determine the optimal hydraulic pressure and blank holder force profiles simultaneously, an adaptive FE analysis with fuzzy control algorithm was developed. Thinning, wrinkling, punch wall contact, die corner floating and conduction were used as criteria in the fuzzy control algorithm. The effects of the determined loading profiles are then presented in terms of thickness, strain and stress, and temperature distributions as well as success/failure of the forming process. The effect of punch speed was also investigated to reveal its impact on part formability. It was found that the optimal process conditions can be rapidly and accurately obtained with the developed adaptive FEA method coupled with fuzzy control algorithm.

Original languageEnglish
Pages (from-to)230-242
Number of pages13
JournalJournal of Materials Processing Technology
Issue number1-3
Publication statusPublished - 23 Jul 2007
Externally publishedYes



  • Adaptive FEA
  • Lightweight materials
  • Loading profile
  • Peclet number
  • Warm sheet hydroforming

ASJC Scopus subject areas

  • Ceramics and Composites
  • Modelling and Simulation
  • Computer Science Applications
  • Metals and Alloys
  • Industrial and Manufacturing Engineering

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