This presentation provides an overview of hydroforming, which uses high-pressure hydraulic fluid to shape ductile metals. There are three types of hydroforming: tube hydroforming uses tubing and reshapes it within a die; sheet hydroforming forms sheets using fluid counter-pressure; and explosive hydroforming uses an explosion to rapidly form large parts. Hydroforming allows for complex, lightweight shapes with tight tolerances and fewer parts compared to conventional structures. However, it has higher costs and slower cycle times than traditional forming methods.

1. PRESENTATION
ON
HYDROFORMING
Under the Guidance of, Presented by,
Er. Kapil Sharma Vishwas Bajpai
Asst. Professor 1447440154
S.S.V.I.T, Bly

2. CONTENTS
 Introduction
 Classification of Hydroforming
 Tube Hydroforming
 Sheet Hydroforming
 Explosive Hydroforming
 Materials
 Applications
 Advantages
 Comparision with Conventional Steel Body Structure
 Disadvantages
 References

3. INTRODUCTION
 It is a specialized type of die forming that uses a high pressure
hydraulic fluid to press room temperature working material
into die.
 It uses water pressure to form complex shapes from sheet or
tube material.
 It is a cost effective way of shaping ductile metals such as
aluminium, brass, low alloy steel into lightweight and strong
pieces.
 The pressure may go upto 60,000psi depending on the
component.

4. CLASSIFICATION OFHYDROFORMING
There are three types of hydroforming process:
i. Tube Hydroforming
ii. Sheet Hydroforming
iii. Explosive Hydroforming

5. TUBE HYDROFORMING

6. Continued…….
 Used when a complex shape is needed.
 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 .

7. SHEET HYDROFORMING

8. Continued……
 Involves forming of sheets with application of fluid
pressure.
 Metal blank is subjected to hydraulic counter pressure
generated by punch.
 Required deformation takes place.

9. EXPLOSIVE HYDROFORMING
 Used for large parts
 Generates the forming pressure by a simple explosion
above the part which is immersed in water.

10. MATERIALS
 Steel (mild and harder steels)
 Stainless Steel
 Aluminum alloys
 Brass

11. APPLICATIONS
 Body shell
 Driving shaft
 Assembled camshaft
 Exhaust systems
 Engine cooling system
 Radiator frame
 Safety Equipments

12. ADVANTAGES
 Extraordinary Design Flexibility
 Fewer Parts
 Less Weight
 Lower Tooling Costs
 Less Post-Processing
 Greater Integrity (pressure flows the metal into corners for
greater precision)

13. COMPARISION WITH COVENTIONAL
STEELBODYSTRUCTURE
 50% less weight
 45% less parts (less tools, less assembly)
 45% less welding seams
 Tighter tolerances

14. DISADVANTAGES
 Slow cycle time
 Expensive equipment and lack of extensive knowledge
base for process and tool design
 Requires new welding techniques for assembly

15. REFERENCES
 www.google.com/hydroforming
 Metal Forming Process by Bouchaib Radi