6x the Speed of ...
Aircraft Relies on Triform for Control & Repeatability
Piper Aircraft provides aviators around the world with efficient and reliable single- and twin-engine aircraft . They had been using rubber pad and sheet hydroforming presses for decades , but their existing tray-style machines required expensive diaphragm changes that took weeks to complete and resulted in extended down-time .
Piper wanted a new hydroforming solution that could accurately form their parts and maximize up-time by offering fast , inexpensive diaphragm changes . Beckwood evaluated Piper ’ s needs and recommended a Triform fluid cell sheet hydroforming press with a 16 ” forming area and 5,000 psi . Their new
16-5FC significantly decreased down-time and increased cost-savings , with diaphragm changes taking less than 30 minutes .
The Triform press also reduced cycle times from 90 seconds to 30 seconds , and tool changes are considerably less cumbersome than those performed on the larger machines .
Piper has transitioned over 500 parts to the new Triform , approximately 20 % of their overall production ! Parts are now formed faster than ever before with quality and precision unattainable on their aging tray-style press .
“ We typically produce 10 to 30 parts per setup , then change tooling ,” said James Priest , lead press operator . “ We might change tools 15 times or more per shift . With the Triform , tool changes literally take seconds . Conversely , changing tools on our larger hydroforming presses can take 30 minutes or more .”
• Simplified Tooling : Since the diaphragm acts as a universal female die , mated tools are not required . This can reduce tooling costs by 50-90 % compared to conventional forming methods ! Dies are easily manufactured from inexpensive materials and typically last longer than mated dies due to the steady , uniform pressure applied during the process .
• Precision Forming : A single operation can form complex geometries , achieve tight tolerances , or complete airtight fits on mated parts while enhancing dimensional precision by reducing spring-back .
• Simple , fast operation : In just minutes , and with minimal training , Triform users can begin forming parts . The simple , user-friendly controls platform allows you to manipulate process variables throughout the forming cycle and save part recipes for quick recall .
Jinpao started as a hard-tooling company in 1998 , but with an aggressive expansion plan , quickly evolved into a leading job shop in Southeast Asia specializing in low-volume , high-mix aerospace part production .
“ To grow with our aerospace customers , we need machinery that can easily form complex shapes , and we need to cut costs for extensive tooling ,” said Jinpao ’ s Managing Director , Victor Chung .
Among the new machinery at Jinpao is a Triform model
24-5FC fluid cell sheet hydroforming press . With a 24 ” diameter forming area and 5,000 psi , Jinpao ’ s new press is one of the most versatile models available on the market today .
“ Originally , we were using conventional stamping machines to form sheet metal parts ,” said Chung . “ It is common knowledge that these methods are prone to tooling marks , wrinkles , scratches , and other cosmetic defects .”
“ With sheet hydroforming , we can form multiple complex designs in a single cycle without extensive tooling ,” said Chung . “ And we were able to cut tooling costs in half because the diaphragm serves as the female die . We ultimately chose Triform because of their total solution .”
• Less Skilled Labor : Sheet hydroforming offers near-net-shape part production in a single cycle , so costly ‘ artisan operators ’ and secondary finishing are not required .
• Increased Efficiency : The large forming area on many Triform presses is able to form multiple parts in a single cycle . Additionally , parts that normally require multiple steps or expensive progressive dies can often be formed quickly through sheet hydroforming .
• Less Scrap : Triform presses result in less than 10 % variation in blank-to-finished part thickness due to uniform elongation of the material being formed . Multidirectional forces draw the blank around the tool , greatly minimizing stretching and thinning .
• Speed : Depending on the machine , Triform customers achieve cycle times as quick as 30 seconds !