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<p>In this paper, a new rolling hydroforming (RH) process is proposed for forming T-shaped tubes to improve the material flow and increase the branch height in the tube hydroforming process. The deformation behavior during free hydroforming (FH) and rolling hydroforming (RH) processes is carried out by combining numerical simulations and experiments. The microstructure evolution and mechanical properties are investigated using electron backscattered diffraction and hardness testing. The results show that, compared to the FH process, the branch height and minimum thickness increase during the RH process by 16% and 7%, respectively. The material in the main tube can be pushed into the branching zone via localized circumferential rolling loading in the RH process. The microstructure characterization reveals that, compared to the FH process, the grain refinement effect is significant, improving the hardness by 4% at the top of the branch through the RH process. Consequently, the RH process can improve the formability compared to the FH process. This process has the potential to be used in the manufacturing of multi-way tubes.</p>

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Deformation Behavior, Microstructure, and Mechanical Properties of T-Shaped Tube during Rolling Hydroforming

  • 期刊论文

  • 发表日期：

    2025年9月18日

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  • Mingtao Chen,
  • Xiaoting Xiao,
  • Hui Long,
  • Yunya Xiao

摘要

In this paper, a new rolling hydroforming (RH) process is proposed for forming T-shaped tubes to improve the material flow and increase the branch height in the tube hydroforming process. The deformation behavior during free hydroforming (FH) and rolling hydroforming (RH) processes is carried out by combining numerical simulations and experiments. The microstructure evolution and mechanical properties are investigated using electron backscattered diffraction and hardness testing. The results show that, compared to the FH process, the branch height and minimum thickness increase during the RH process by 16% and 7%, respectively. The material in the main tube can be pushed into the branching zone via localized circumferential rolling loading in the RH process. The microstructure characterization reveals that, compared to the FH process, the grain refinement effect is significant, improving the hardness by 4% at the top of the branch through the RH process. Consequently, the RH process can improve the formability compared to the FH process. This process has the potential to be used in the manufacturing of multi-way tubes.