Date of Award

Spring 2018

Project Type


Program or Major

Mechanical Engineering

Degree Name

Master of Science

First Advisor

Yannis Korkolis

Second Advisor

Brad Kinsey

Third Advisor

Todd Gross


This is a thesis on the development of an experimental table-top sized tube hydroforming machine at the University of New Hampshire. This thesis documents the design of the machine and the exploration of the forming envelope of the device via finite element modeling of the forming process. Several experiments on Al-6061-T4 tubes were used to evaluate the plastic behavior and strain limits of the tube in the axial and circumferential (hoop) directions. Two of these material tests, the uniaxial tension test and the ring hoop tension tests, were simulated with finite element models to refine the Al-6061-T4 plasticity curve, including the extrapolation of the hardening curve beyond the point of ultimate tensile stress. 2D and 3D finite element models of the hydroforming process were also used to evaluate potential tube materials, outer diameters, and wall-thickness for future experiments and research efforts.