This seminar report discusses the hydroforming process. Hydroforming uses liquid pressure to form complex metal shapes. There are two types: tube hydroforming forms tubing, while sheet hydroforming forms sheet metal. Hydroforming offers advantages over conventional forming like reduced weight, fewer parts, and tighter tolerances. It is increasingly used in automotive and aerospace industries. The report provides details on the different hydroforming techniques, design considerations, materials used, and economics of hydroforming.

1. A
Seminar Report
On
HYDROFORMING
Guided By ;D.H.Patel
Prepared by :Patel Mehul.A
Patel Jay

2. OUTLINE:
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What is Hydroforming
Types of hydroforming
Application
Design Considerations
Advantages/Disadvantages
Economics of Hydroforming
Reference Websites and Links
Conclusion

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

5. Tube Hydroforming
a
b
c
d
e
f
Faxial
Faxial
P

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.

9. APPLICATIONS
• Automotive industry
• Sanitary use
• Aerospace
– Lighter, stiffer parts
Chevy SSR Frame

10. APPLICATIONS (CONT)
1. Body shell
2. Driving shaft
3. Assembled camshaft
4. Exhaust systems
5. Engine cooling system
6. Radiator frame
7. Safety requirements
8. Engine bearer
9. Integral member
10. Cross member
11. Frame structure parts
12. Axle elements

12. MATERIALS
• Steel (mild and harder steels)
• Stainless Steel
• Aluminum alloys

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

14. DESIGN CONSIDERATIONS
Product
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Geometry, thickness distribution
Dimensional accuracy/tolerances
Surface finish
Microstructure, mechanical and
metallurgical
properties, hardness

15. Tool/Dies
-Geometry of tools
- Material hardness
- Surface conditions
- Stiffness and accuracy

16. Equipment
- Press capacity
- Speed/production rate
- Force/energy capabilities
- Rigidity and accuracy

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.

22. ECONOMICS

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!