FOCUS ON HYDROFORMING
Sheet hydroforming benefits
Hydroforming technology ( Gestamp ).
■ Complex and irregular shapes can be formed .
■ Accurate and repeatable forming .
■ Reduced reliance on skilled labour .
■ One comprehensive tool ( no mating part is needed ).
■ Uniform elongation of material .
■ Thinner materials can be used for the blank , resulting in a lighter end product .
■ Multi-directional force to reduce stretching or thinning .
■ Complex , net-shape parts formed in a single cycle .
■ Short set-up times and reduced waste .
■ Eliminate multi-step processes .
■ Smooth finishes , with little to no secondary processing .
secondary processes . The parts can be as thin or as thick as the original design demands , and it can have complex joints , threads and formations ,” commented manufacturer , Helander .
Tube hydroforming ( THF ) is a cold forming process to form a hollow part with different cross sections along its length by applying an internal hydraulic pressure and forcing the tubular blank to conform to the shape of a given die cavity . It is a specialised type of coldforming technique that uses a high-pressure hydraulic fluid to press tubes into a die at room temperature .
“ The main advantage of hydroforming is that it allows complex shapes with concavities to be formed , which would be difficult or impossible with standard stamping ,” commented stamping specialist , Gestamp . “ Tube hydroforming technology is vital for some key parts of chassis and body in white , even more now with so many electric vehicle projects entering the market . This technology allows us to manufacture lighter parts which have better performance and stiffness , because its application transforms different sections along the length of the tube .”
Tubular hydroforming is used when complex
Hydroforming ’ s broad design freedom ; high material utilisation ; reduced part weight ; high mechanical strength and improved dimensional accuracy contributes to its popularity
components , such as curved sections , are needed . Examples include truck / car door handles and bicycle frames etc .
In conclusion
Hydroforming technology is well suited to structural items , from small and shallow to large and deep parts in various materials ( such as aluminium alloys , stainless steel and titanium ). It is used , for example , for engine components , including deep drawn parts , in high-strength , heat-resistant materials . It is also employed for the expansion forming of tubes , ducts and other irregularly shaped parts .
Complex , close-tolerance parts can be produced , often in one operation . The process also offers higher productivity levels , as multiple parts can be processed in a single cycle . Faster lead times also result , with quick tool set-up .
If electrodes are used to vaporise the fluid explosively in an arc , this describes a similar process known as electro-hydraulic forming . For large parts , explosive hydroforming can generate the forming pressure by simply exploding a charge above the part ( complete with evacuated mould ) which is immersed in a pool of water . The hydroforming-into-a-mould process also works using only a shock wave in air as the pressuring medium .
“ Hydroforming ’ s broad design freedom ; high material utilisation ; reduced part weight ; high mechanical strength and improved dimensional accuracy contributes to its popularity as the chosen manufacturing method for many industries such as automotive , lighting and appliance industries ,” concluded Metalcraft Spinning and Stamping . n
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