FOCUS ON HYDROFORMING
Flexform TM , also called fluid cell forming , sheet-metal forming ( Quintus Technologies ).
and fuel-efficient vehicles . Hydroformed parts can be used to create complex and intricate shapes ( e . g . the Chevrolet Corvette Stingray uses a hydroformed aluminium chassis ).
“ One of the main trends in the automotive industry is the increasing demand for lightweight vehicles . This is being driven by stricter emissions regulations , as well as the need to improve fuel economy . Hydroforming is an ideal technology for manufacturing lightweight parts , as it allows for complex shapes to be created with minimal material waste . This is especially important for electric vehicles , which need to be as lightweight as possible to maximize range . For instance , Ford F-150 uses a hydroformed structural cage , made of high-strength steel , in its F-150 pick-up trucks . This eliminates the need for welding , which reduces weight and improves strength ,” added the analyst .
Market opportunities include the increased integration of Advanced Driver Assistance Systems ( ADAS ); hydroformed parts can provide the necessary structural support
Sheet hydroforming benefits
■ 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 .
■ Eliminates multi-step processes .
■ Supports sustainable manufacturing processes .
■ Smooth finishes , with little to no secondary processing . and mounting solutions for these advanced systems . The growing adoption of electric vehicles ( EVs ) means an increasing need for EV charging infrastructure . Hydroformed parts can be used to manufacture components such as charging station housings , mounting brackets and cable management systems .
Market restraints , cited the analyst , included the lack of standardised design guidelines and manufacturing processes for hydroformed parts as well as higher levels of complexity on manufacturing times .
Sheet hydroforming
Sheet hydroforming is a metalforming process that uses pressurised hydraulic fluid in a flexible diaphragm to shape sheet metal against a single , un-mated tool . The process can create a wide range of complex geometric shapes from a variety of materials including aluminium ; steel ; stainless ; titanium ; niobium ; Inconel ; copper ; composites and more . “ Sheet hydroforming presses can combine
Hydroformed longitudinal beam .
A hydroformed part .
Image : MSM Aerospace Fabricators .
or even replace different metal forming processes including spinning ; press-brake forming ; traditional draw forming ; rubber pad forming ; progressive die forming and more . These machines can also consolidate multiple steps into a single cycle , virtually eliminating secondary finishing processes such as polishing , annealing or welding ,” added press manufacturer , the Beckwood Corporation .
The two primary types of sheet hydroforming presses are fluid cell and deep draw . Fluid cell presses create shallow parts with open corners while deep draw presses are used for taller parts with closed corners . Deep draw hydroforming machines use pressurised hydraulic fluid ( either water or oil ) to force sheet metal into or around a single solid mould . The hydraulic chamber is sealed by a flexible rubber diagram , which acts as the female portion of the tooling and can be paired with any mould .
Rubber pad forming is a deep drawing technique that is suitable for the production of small and medium-sized batches .
The uniform pressure exerted by the diaphragm in sheet hydroforming is suitable for creating complex geometric shapes which can be difficult to create using traditional forming methods . Parts that normally require multiple steps or expensive progressive dies can often be formed in a single cycle through sheet hydroforming . Cans , boxes or parts with curved flanges , which have a tendency to wrinkle , also benefit greatly from the controlled flow of material .
Image : Schuler .
32 | ismr . net | ISMR September 2024