HYDROFORMING

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HYDROFORMING
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OUTLINE
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HYDROFORMING

• A special type of die forming using a high
  pressure Hydraulic fluid to press room
  temperature working material into a die

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History

• Discovered by HOLMSTROEM, MARTIN

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There are three types of hydroforming 1.
Tube hydroforming 2. Sheet
hydroforming 3. Explosive hydroforming
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TUBE HYDROFORMING

• 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
  

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SHEET HYDROFORMING

• Involves forming of sheets with application of
  fluid pressure
• Metal blank is subjected to hydraulic counter
  pressure generated by punchs
• Required deformation takes place
• Note Sheet hydroforming provides a
  work-hardening effect as the steel is forced
  against the blanks through fluid pressure.

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Explosive hydroforming

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

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THE APPLICATION SPECTRUM

• 1. Outer skin with its extreme demand of surface
  quality and dimensional accuracy.
• 2. Longer outer skin parts for passenger cars,
  utility vehicles
• 3. Low capital cost. Fewer and simpler dies.
• 4. Better NHV (noise, vibration and harshness
  )factors.
• 5. Reduction in weight.
• 7. High process capability.
• 8. Reduction in cost of component.

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MATERIALS

• Steel (mild and harder steels)
• Stainless Steel
• Aluminum alloys
• Research continues to expand the capabilities of
  the hydroforming process

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ADVANTAGES

• Extraordinary Design Flexibility.
• Fewer Parts
• Less Assembly
• Less Weight.
• Lower Tooling Costs.
• Less Post-Processing
• Greater Integrity (pressure flows the metal into
  corners for greater precision rather than
  streching)

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ADVANTAGES (CONT.)

• Results compared to conventional
  steel body structure
• 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)
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DISADVANTAGES

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

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ECONOMICS
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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!

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QUESTIONS???