3. HYDROFORMING
Hydroforming is a manufacturing process
where liquid pressure is used to form
complex shapes.
There are two types of hydroforming:
1) Tube hydroforming
2) Sheet hydroforming
4. TUBE HYDROFORMING
• Used when a complex
shape is needed.
Outer tool part
Section A - A
Tube
• A section of cold-rolled
steel tubing is placed in a
closed die set.
• A pressurized fluid is
introduced into the ends of
the tube.
• The tube is reshaped to the
confine of the cavity.
Inner tool part
Upper tool part
not shown
7. SHEET HYDROFORMING
• Sheet steel is forced into a female cavity by water
under pressure from a pump or by press action
• Sheet steel is deformed by a male punch, which acts
against the fluid under pressure.
13. DESIGN CONSIDERATIONS
• Hydroforming is generally defined as either lowpressure or high pressure.
• The demarcation point is 83MPa
• Constant pressure volumetric expansion
< 5% required to shape the part = Low pressure
> 5% (but < 25%) = High Pressure
17. Work piece/Material
-Flow stress as a function of strain, strain rate and
microstructure
-Workability as a function of strain, strain rate
and microstructure
- Surface conditions
- Geometry of tubing ( outside diameter, tube wall
thickness, roundness, properties of welding line,
etc.)
18. Deformation zone
-Deformation mechanics, model used for
analysis
- Metal flow, velocities, strain rates,
strains (kinematics)
- Stresses (variation during deformation)
19. ADVANTAGES
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Hydroforming draws material into the mold
Part consolidation
Weight reduction through more efficient
section design and tailoring of the wall
thickness
Improved structural strength and stiffness
Lower tooling cost due to fewer parts
Fewer secondary operations (no welding of
sections required and holes may be punched
during hydroforming)
Tight dimensional tolerances and low spring
back
Reduced scrap
20. ADVANTAGES (CONT.)
Results compared to conventional steel body structure:
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50% less weight
45% less parts (less tools, less assembly)
45% less welding seams
Tighter tolerances
Volvo Hydroformed Structure concept in Aluminum,
(Schuler Hydroforming 1998)
21. DISADVANTAGES
• Slow cycle time
• Expensive equipment and lack of extensive knowledge
base for process and tool design
• Requires new welding techniques for assembly.
23. INFORMATION ON THE WEB
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www.hydroforming.net
www.vari-form.com
www.hdt-gti.com
www.revindustries.com
www.autosteel.org
www.schuler-hydroforming.de
www.egr.msu.edu/~aenader
nsmwww.eng.ohio-state.edu/html/tube_hydroforming.html
24. CONCLUSION
• Hydroforming is an innovative forming process
• Hydroforming is becoming more popular
(ie.automotive and aerospace industries)
• The advantages outweigh the limitations
• Material selection is broad and continues to increase
• Information can be found everywhere!