Materials and Design 32 (2011) 19571966

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Materials and Design

journal homepage: www.elsevier.com/locate/matdes

A study of the braided corrugated hoses: Behavior and life estimation

H. Hachemi a,b,, H. Kebir a, J.M. Roelandt a, E. Wintrebert b
a
b

Roberval Laboratory, Universit de Technologie de Compigne (UTC), BP 20529, 60205 Compigne Cedex, France
BOA Flexible Solutions, 14 rue de la Goutte dOr F-02130 Fre-en-Tardenois, France

a r t i c l e

i n f o

Article history:
Received 14 July 2010
Accepted 30 November 2010
Available online 8 December 2010
Keywords:
Fatigue
Residual stress
Braid

a b s t r a c t
This work presents the virtual simulation of the hoses hydroforming; the main objective is to predict
when and where cracks can appear during a cyclic loading.
A methodology has been proposed to investigate the effects of plastic strain and residual stress after
hydroforming on cyclic life fatigue.
First, an axisymmetric simulation of the hydroforming of exible metal hoses was accomplished using
the nite element method, then a cyclic loading is applied, nally the life cycle is estimated using a model
based on Chaboches model.
The results are compared with experimental data, a good agreement is found if we take in account the
residual stress and the hardening due to hydroforming.
A mechanical behavior model has been developed to study the braid which is the second element of the
braided corrugated hoses; they are added to corrugated hoses in order to improve its radial and axial
stiffness.
2010 Elsevier Ltd. All rights reserved.

1. Introduction
Flexible corrugated hoses of stainless steel (Fig. 1) are mechanical components which are used in many applications, for example
they are used to minimize the effect of vibrations on piping and car
engines, doing well for this purpose, these components can suffer
dynamic loads from gas and liquid pulsation and fail.
It is well-known that the metallic material is subjected to large
irreversible deformation in hoses hydroforming, this leads to high
strain and high stress localization areas, these two parameters
have great impact on cyclic life fatigue of the hydroformed hoses
[112].
Signicant advances have been made in recent years for obtaining more accurate and reliable determinations of residual stress
distributions. These include both experimental and numerical
methods [1316].
The failures of the corrugated hoses frequently happen in the
form of small holes or cracks, therefore the conditions of leak before break is generally most frequent in prediction of damage; this
enables the reduction of the failure consequences in a working
environment [17]. Wang et al. [18] studied the effect of stamping
on fatigue life FEM prediction using plastic strain and thickness
variation Zapatero et al. [19] studied the inuence of maximum
load, the crack length and stress ration on the fatigue crack closure
Corresponding author at: Roberval Laboratory, Universit de Technologie de
Compigne (UTC), BP 20529, 60205 Compigne Cedex, France. Fax: +333 44 23 46
89.
E-mail address: hakim.hachemi@utc.fr (H. Hachemi).
0261-3069/$ - see front matter 2010 Elsevier Ltd. All rights reserved.
doi:10.1016/j.matdes.2010.11.075

by means of nite element analysis. Matsui et al. [20] explored the

inuence of strain ratio on bending fatigue life and fatigue crack
growth in TiNi shape-memory. Li et al. [21] used the nite element
method to simulate the cyclic stress/strain evolutions for multi-axial fatigue life prediction. Marakami et al. [22] studied the effect of
hydrogen on cracks propagation of SUS316L exible hoses of
hydrogen station, Marron et al. [23] dealt with the effect of forming
in the design of deep drawn structural.
The objective of this study is to improve the fatigue analysis
using nite element method considering effects of hydroforming
(residual stresses and plastic hardening) on cyclic life fatigue of
corrugated hoses.
In addition to the accurate parameters of fatigue damage models, the investigations of this work showed that the accurate estimations of the cyclic stresses, residual stresses and plastic strains
after hydroforming are very important to have an accurate estimation of fatigue life, thus a performant element and a rened mesh
are required to do the analysis.

2. Hydroforming effects of the corrugated hose

The case selected in this study is a corrugated hose used in automobile engines; the corrugated hose is manufactured from a
straight tube. The original blank is a stainless steel tube (AISI
316L), the mechanical properties are shown in Table 1 and the
hardening curve is shown in Fig. 2, The initial thickness of
the tubes 0.25 mm. A non-linear FEM code is used to simulate
the hydroforming process.

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H. Hachemi et al. / Materials and Design 32 (2011) 19571966

preforming step is made without tools displacements then a second forming, using the same pressure as in the preforming, with
tools displacement is performed, nally the pressure is canceled
and the tools are removed.
In order to validate our simulation, the geometrical dimensions
after hydroforming are compared to the measured one; as we can
see in the Table 2, the Geometrical dimensions carried out from the
simulations are very close to the measured dimensions; in fact the
maximum error does not exceed 1.2%.

3. Fatigue FEM analyses for the hydroformed tube

To study the fatigue behavior of corrugated hoses, we subject
them to alternated cycles of axial loading of traction and compression without internal pressure. Fig. 5 shows the hose after compression and elongation.
To take into account the tensorial character of the stresses, a
ow surface of fatigue in terms of ow surface in plasticity is dened Eq. (1), chaboche has already dened a fatigue model for a
multi-axial fatigue [25]:
Fig. 1. Corrugated hose after hydroforming.

Table 1
Mechanical properties of AISI 316L.
Young modulus
Yield stress
Tensile strength
Poisson coefcient
Density

193000 Mpa
250 Mpa
1170 Mpa
0.3
7800 kg/m3

ff AII  AII

r


1 3  dev
v
v
dev
rijmax  rde
rde
AII
ijmin
ijmax  rijmin
2 2
r
i
1h
a1  a2 2 a2  a3 2 a3  a1 2

dev
The damage starts when ff becomes positive, rdev
ijmax ; rijmin are
respectively the maximum and minimum deviatoric tensors of
stresses in a cyclic loading, the amplitudes of the principal stresses
are dened as:

ai Dri =2

The present model is based on the criteria of Sines [25,26], the

most general criteria so we can write:

H
AII rl0 1  3br

 H is the average of the hydrostatic stress in a cycle load, r0

where r
 0) and b is a
is the ultimate stress in alternative fatigue (when r
material coefcient.
The damage evolution for a tensorial stress can be expressed as
it is given for one dimension stress [25]:

dD 1  1  Db1 aAII ;rH ;reqMax



Fig. 2. Stressstrain curve: INOX 316L.

An eight-node axisymmetric element with nine point of integration is used to simulate the hydroforming process, this element
is the most powerful element in axisymmetric calculus; it gives
more accurate results for less rened mesh both for geometric
non-linearity and plasticity [24]. The focus of this study is to include the hydroforming effects of plastic strains and residual stresses in the subsequent fatigue FEM model. Fig. 3 shows the effective
plastic strain and the Von Mises residual stress. The axisymmetric
element is used in the simulation of the hydroforming process for
the consideration of time saving.
The hydroformed hose is made by multiple steps (see Fig. 4),
rst the straight tube is xed by tools called anges, after that a

AII
M1  D

B
dN

 H
M M 0 1  3br


AII  AII
a1a
ru  reqmax
r!
3 dev
reqmax max
r : r dev
2


1
1
reqMax Max p r1  r2 2 r2  r3 2 r3  r1 2 2
2

5
6
7
8
9

ru is the tensile strength, a, M0, b are material parameters dened

by Wohler curves.
After integration of Eq. (5), the fatigue life Nf is dened as a
function of the amplitude of the stress:
 b
Nf

AII
M

b 11  a

10

As in one dimension [25,26], we can introduce the inuence of initial hardening on the coefcients: ru ; AII ; M.

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H. Hachemi et al. / Materials and Design 32 (2011) 19571966

Fig. 3. Plastic strain and residual stress after hydroforming.

Fig. 4. Hydrofoming steps.

Table 2
Geometrical dimensions for PARNOR 1 in. and PARNOR 6 in.

Inner diameter
Thickness
Outer diameter
Pitch

PARNOR 1 in. (mm)

PARNOR 6 in. (mm)

Measure

Simulation

Measure

Simulation

25
0.20/0.24
36
7.1

24.95
0.22/0.25
36.01
7.0

150
0.45/0.485
174
15.70

149.95
0.47/0.5
173.8
15.60

AII  AII q
ru q  reqMax
H
AII r0 1 k1 :Zc1  3br

arM ; q; r 1  a

ru q ru0 1 k2 zc
Mq M 0 1 k3 Zc
p
Zc c


11
12
13
14
15

k1, k2, k3 are coefcients which are obtained from experiments, the
values of ru0, rl0 were xed from the experimental Wohler curves

Fig. 5. Stresses after compression and elongation for Xf = 6 mm (PARNOR 1 in.).

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H. Hachemi et al. / Materials and Design 32 (2011) 19571966

Table 3
Materiel coefcients.
Parameter

rl0

r0

k1

k2

k3

M0

Value

1170 Mpa

222 Mpa

0.4

2.2

1.6

1650 Mpa

0.9

0.25

[25], 316L Steel has the coefcients values shown in Table 3. For the
tests with an initial hardening, c is equal to the initial effective plastic strain.
First we assess the life cycle fatigue at each integration point of
each element of the modelized corrugated hose. The life cycle of
the tube is the minimum of the fatigue lives for each integration
point. The stress used in life cycle estimation is the algebraic
sum of the residual stress and the stress due to cyclic loading.
the organigram of this method is shown in Fig. 6.

4. Experiment results
In order to validate the model, we have performed some experiments, see Fig. 7.
Each hose used in these tests have 10 waves, for every
displacement Xf, a sample of six hoses is used to get the mean life
time.
The numbers of cycles indicated correspond to the appearance
of a crack which we can see by eyes in the corrugated tube.

Fig. 7. Fatigue test (BOA group).

5. Comparison of estimations with experimental ndings and

discussion
Comparative results for two hoses (dimension 1 in. and 6 in.) at
different axial displacement Xf are presented in Figs. 8 and 9.

Fig. 6. Fatigue estimation algorithm.

H. Hachemi et al. / Materials and Design 32 (2011) 19571966

Fig. 8. Comparison tests/computed values (PARNOR 1 in.).

1961

The difference between the estimation results and the experimental results is due to several parameters, rst The assumed
assumptions in the simulation, for more correct results we must
take into account all the manufacturing processes of the tube in
simulation (rolling, welding. . .etc.), these processes give residual
stresses and strains which could be added to the hydroforming
strains and residual stresses, also the results obtained by experiment are for large cracks whereas those obtained by estimation
are for micro cracks, secondly we can attribute the differences between the experiment and computation results to the damage
model used in calculations; indeed it is difcult to identify the constants of the model of damage with sufcient precision. Finally a
rened mesh is required to get more precise stresses and strains
which are very important in the estimation of cylic life fatigue.
As shown in Fig. 10, the calculated fragile area corresponds well
to the experiments
 it is located in the hollow of the wave, close to the blank, on the
external surface of corrugated hose for the PARNOR 1 in.
 it is located in the hollow of the wave, on the interior surface of
the corrugated hose for the PARNOR 6 in.
6. Braid modeling

Fig. 9. Comparison tests/computed values (PARNOR 6 in.).

It is well seen that the computation results can be used to predict the life fatigue estimation of tubes in a given loading condition; in fact the estimated values are lower than those carried
out by experiment.

The second part of our work is to model the braid which is the
second most important part of the corrugated braided hoses. This
part is used to improve the radial and axial stiffness of the tube.
Extensive investigation of textiles has been conducted these the
last two decades, Most of these efforts were concerned with
weaves with orthogonal tows, modeling based or not on the nite
element method have been developed to characterize the effective
engineering properties [2737] and few focused on braids [3845],
but the braids in the form of tubes, as shown in Fig. 11, are less
studied especially to get a macro mechanical behavior.
The braid is manufactured by the diagonal intersection of several units of wires which are called spindles, in the conventional
machine of braiding, half of the bundles turn clockwise and other
half in the counterclockwise direction, and different braids are
manufactured as shown in Fig. 12. [46,47].
In this study, we present a non-linear macro mechanical behavior for 2  2 helicoidal braid.
6.1. Linear elastic behavior of the braid, Hookes law
6.1.1. Density of the braid
The density of a braid is dened as the volume of the braid divided by the volume of the enveloping cylinder:
2

U
N1  N 2 cos
a

D 5U2  D2

where
N1: The number of spindles
N2: The number of wires of each spindle
U: The diameter of wire
a: The angle of braiding
Fig. 10. Crack initiation area: simulation and experiment for PARNOR 1 in.

Fig. 11. The braid used in experiment.

16

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H. Hachemi et al. / Materials and Design 32 (2011) 19571966

Fig. 12. Braiding procedure.

Fig. 13. Change of the coordinate system.

D: The external diameter of hose (internal diameter of the

braid))
6.1.2. Stiffness matrix of the braid
By using the Hooks law and the denition of the density we
get:
The stiffness matrix in the case of one spindle (in the global
coordinate system (y0 , z0 ))

C wires
ljkl

2
60
E  cos4 a
E  sin a cos2 a E  cos3 a sin a
6
6
2
4
2
6 0 E  sin a cos a
E  sin a
E  cos3 a sin a
6
60
0
0
0
6
6
40
0
0
0

E  sin a cos a

E  sin a cos a

0
0
0
0
0

By taking two spindles and adding the radial stiffness, we nd the

stiffness matrix of the braid in the global coordinate system
(x0 , y0 , z0 ) (see Fig. 13):

C braid
ijkl

6
6
6
6
6
6
6
6
4

En

0 0
2

2  E  n  cos4 a

2  E  n  cos2 a sin a

2  E  n  cos2 a sin a 0 0
2  E  n  sin a

0 0

0 0

0 0

0 0

6.2. Variation of the angle

When the corrugated hose is subjected to internal pressure,
the braiding angle a decreases under the effect of this
elongation.
By means of some mathematical operations we can nd a relation between the variations of the angle a and the longitudinal
strain e22 in the global coordinate system (see Fig. 14b).

e11 3
7 6 e22 7
0
7 6
7
7 6
7
7 6 e33 7
0
76
7
7
7
6
0
7 6 c12 7
7 6
7
5 4 c13 5
0
2
c23
E  cos2 a sin a
0

The longitudinal strain e22 is calculated from the length variation of the braid.

e11 3
7 6 e22 7
0
7 6
7
7 6
7
7 6 e33 7
0
76
7
7 6c 7
0
7 6 12 7
7 6
7
5 4 c13 5
0
2
c23
2E  n  cos2 a sin a
0

H. Hachemi et al. / Materials and Design 32 (2011) 19571966

Fig. 14. Representative unit cell (left) and braiding angle change (right).

Fig. 15. Implementation in ABAQUS.

1963

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H. Hachemi et al. / Materials and Design 32 (2011) 19571966

Fig. 16. Evolution of the braid during traction and numerical simulation results.

da

e22  sina  cosa

1 e22  cos2 a

17

With:

e22

dp
p

18

q
OA0 cosa  da  dP cosda  p2 PD2
p
ef cosa  da  q e22 cosda  1
p2 PD2

ef cosa  da  cosa  e22 

da2
2

19
20

21

6.3. The elongation of the braid yarns

6.4. Variation of the braid diameter and length

An elongation dp of the braid causes automatically elongations

of the yarns.
Using some mathematical operations we can nd a relation between the yarn strain, the current braiding angle and the longitudinal strain:

When the pressure loading is applied the braid elongates without plastic deformation until it reaches a critical angle ac.
The relation between the initial diameter D0, the current radius
D, the current and initial angle a and a0, is obtained by using the
representative unit cell (see Fig. 14a).

H. Hachemi et al. / Materials and Design 32 (2011) 19571966

1965

of cycles decreases, taking into account residual stresses

allows more accurate results, the numerical estimation are
lower than the experimental results (23 times). The localization of the crack weak area was detected, this presented
modeling shows good agreement with experimental results
and may be used by hoses designers to predict and improve
hydroformed hoses performance.
(b) In the second part of this work a modal has been developed
to simulate the behavior of the braid subjected to axial loads,
the curve force/elongation shows very good agreement with
experiment until 10% of elongation (25 mm) where we have
the lock of the cells of the braid.
(c) This modeling can be used to study the braided corrugated
hoses under internal pressure to estimate the fatigue life of
braided hoses. The modeling could be improved by taking
into account the plasticity of the wires after cells lock.
Fig. 17. Braid elongation/applied force.

D D0

sin2b
sinb20

D0

References

sina
sina0

22

The same thing can be done for the length:

L L0

cos2b
cosb20

L0

cosa
cosa0

23

The cell locks when S 0 and we get ac

 
1
W
 arcsin
2

24

where is the length of the unit cell measured along the tows and W
is the width of the spindles.
The model has been incremented in ABAQUS using the UMAT
subroutine, as shown in Fig. 15.
A traction test on a universal testing machine was carried out to
validate the developed model; the measures are taken from three
different positions, the Fig. 16 illustrates this test.
The Characteristics of the braid used in testing and simulation
are:
Length of the braid
(mm)
Diameter to be
braided (mm)
Diameter of wire
(mm)
Number of wire by
spindles
Number of the
spindles
Braiding pitch (mm)

250
41

External diameter (mm)

43

0.4

Density (compactness)

0.54

10

Braiding angle

37.17

48

Length of wire for 1 m

of braiding
Mass of braid (kg/m)

1.25

174

0.6

As we can see in the force/elongation curves (see Fig. 17): we have a

very good agreement until we reach 25 mm of elongation which
corresponds to 10% of elongation, this divergence between the
curves is due to the lock of the cells, this lock induce plasticity
and hard contact of wires.
7. Conclusions
On the basis of the research on corrugated hoses, this paper carried out simulations on hydroforming, estimation cyclic life fatigue
then modeling braid behavior under external loading, and the following conclusions were drawn:
(a) In this work a methodology for estimating cyclic life fatigue
has been developed, as the elongation increase the number

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