Hydroforming process aids to improve the manufacturing of automobile parts and reduce industrial waste, utilization of the product, increase the efficiency of a plant, recycling efficient disassembly etc.

1. STUDY OF HYDROFORMING
PROCESS
PRESENTED BY
Mr CHETAN P. PATIL

2. OUTLINE
1. INTRODUCTION
2. WHAT IS HYDROFORMING ?
3. HISTORY
4. TYPES OF HYDROFORMING
5. TUBULAR HYDROFORMING
6. GENERAL STEPWISE PROCEDURE OF TUBULAR
HYDROFORMING PROCESS
7. SHEET HYDROFORMING PROCEESS
8. PROPERTIES OF MATERIALS USED FOR
HYDROFORMING
9. ADVANTAGES
10. DISADVANTAGES
11. APPLICATIONS
12. CONCLUSION

3. INTRODUCTION
 The main work of engineer and scientist is the
development of newer method.
 Aims behind such work are:
 Economic consideration.
 Replacement of old method with new.
 To get high accuracy and surface finish.
 To meet the requirements to machine hard and
costly materials of industries newer methods are
developed by engineers and scientists.
 These machining method is known as “Modern
methods of machining”.

4. WHAT IS HYDROFORMING ?
 Hydroforming is a high-pressure deformation
process that shapes metal sheet or tube into a
predefined geometry by using a fluid under high
pressure.
 These is a special type of die forming process, use
high pressure hydraulic fluid to press room
temperature working material into a die.
 One of the distinct features of hydroforming is that
the pressure exerted on the workpieces is uniformly
distributed.

5. HISTORY
 This process is based on the 1950s patent for
hydra moulding by Fred Leuthesser.
 Going back to 1950, this process used for
superplastic forming, explosive forming, rubber
forming and other lightweight materials
 The first industrial application of this process, for
production of T-shaped joint (Tube Hydroforming),
were published in paper 1960.
 Recent innovations aimed to improve hydro forming
technology by reducing initial investment cost,
increasing production rate, and material utilization.

6. TYPES OF HYDROFORMING
HYDROFORMING
PROCESS
TUBULAR
HYDROFORMING
LOW PRESSURE
HYDROFORMING
HIGH PRESSURE
HYDROFORMING
PRESSURE
SEQUENCE
HYDROFORMING
SHEET
HYDROFORMING
RUBBER DIAPHRAGM
HYDROFORMING
ACTIVE HYDRO
MECHANICAL
DRAWING

7. TUBULAR HYDROFORMING
 Tubular hydroforming changes the cross sectional
shape normal round to the other shape that
changes along with the part length.
 It is more suitable for manufacturing of aluminum
bicycles frames, suspension, radiator support,
discharge pipes of automobiles etc.
 Pressure range used in tubular hydroforming is
from 828 bar (12,000 psi) to 6895 bar (100,000 psi).

8. TUBULAR HYDROFORMING

9. GENERAL STEPWISE PROCEDURE OF
TUBULAR HYDROFORMING
STEP 1
Cut the proper length of straight metal tube
called blank and bend to insert in die cavity.
STEP 2
Bended blank is inserted into die cavity and high
pressurized water is supplied.
STEP 3
Remove the component from die cavity and
perform second area operations.

10. GENERAL STEPWISE PROCEDURE OF
TUBULAR HYDROFORMING

11. SHEET HYDROFORMING
 Sheet hydroforming cycle time is relatively slow
compared to conventional stamping process.
 Common methods of sheet hydroforming are:
 Rubber diaphragm hydroforming
 Active hydro mechanical drawing
 Pressure range used in sheet hydroforming is from
345 bar (5,000 psi) to 1034bar (15,000 psi).
 The fluid (water) pressure effectively punches the
sheet firmly against punch to form required shape.

12. SHEET HYDROFORMING

13. PROPERTIES OF MATERIALS USED
FOR HYDROFORMING
 Good fatigue property.
 High energy absorption capacity.
 Acceptable corrosion resistance when coated.
 Excellent forming property.
Material used for hydroforming include.
 Stainless steel.
 Aluminium.
 Copper and copper alloys.

14. ADVANTAGES
 Low capital cost.
 Reduction in cost of component.
 There are number of automotive components made
by hydroforming.
 Improved structural strength.
 Extraordinary design flexibility.
 Versatile In Forming Complex Shapes And
Contours.

15. DISADVANTAGES
 Slow cycle time.
 Lack of extensive knowledge for tool design.
 Require new welding technique for assembly.

16. APPLICATIONS
 Main applications of tube hydroforming can be
found in the automotive and the aircraft industries.
 Automotive industry
 Chassis frames
 Exhaust system
 Radiator frame etc.
 Sanitary use
 Pipe with varying diameter.
 T-joints.
 Aerospace
 Light weight parts.

17. CONCLUSION
 Due to introduction of hydroforming it is now
possible to use lightweight aluminium structure
instead of the conventional heavy weight steel
structure in automobiles.
 Hydroforming facilitates manufacturing of a single
large complex component instead of many small
components, reducing the tooling costs by 50%.
 Hydroforming is more popular in automotive
industry and aerospace industry.

18. REFERENCES
 Research paper
 Ahmetoglu, M., Altan, "Tube Hydroforming, State of the
Art and Future Trends", Journal of Materials Processing
Technology, Vol. 98, No.1, 2000.
 Masaaki MIZUMURA, Osamu HONDA, “Development
of Hydroforming Technology”, Nippon Steel Technical
Report, No. 90, 2004.
 Muammer Koç, “Advances in Tube Hydroforming - An
Enabling Technology for Low-Mass Vehicle
Manufacturing”, Tsinghua Science And Technology
ISSN, Vol. 9, No. 5, 2004.
 Websites
 http://www.hydroforming.net/hydro/home/en/