Optimizing sheet hydroforming process parameters with a focus on sustainability

Sheet hydroforming (SHF) is a widely used metal forming process in aerospace and automotive industries due to its ability to produce complex shapes with near-net accuracy. SHF process parameters are usually optimized focusing on outputs such as shape accuracy and thickness distribution. However, in response to the increasing regulatory focus on energy efficiency and sustainability, integrating environmental performance into SHF optimization has become crucial. This study focuses on identifying proper environmental indicators, determined by means of life cycle assessment (LCA) and on analyzing them to assess their influence on the determination of the SHF workability window. SHF tests were conducted in different working conditions by varying the forming temperature and the oil pressure rate. For each test, thickness distribution and shape accuracy were considered as outputs for evaluating the manufacturing performance, whereas LCA models were used to assess the potential for the related direct and indirect environmental impact. Then, the most appropriate environmental outputs to be integrated into the process evaluation framework were determined.