PowerPointPrsentation

1

• Project Presentation

• Micro hydroforming and the machine

Prof. Dr. Christoph HartlManufacturing
Technology LaboratoryCologne University of
Applied Sciences
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• Manufacturing Technology Laboratory

• Part of Institute of Production at the Faculty of
  Automotive Systems Engineering and Production
  Engineering of Cologne University of Applied
  Sciences
• Managed by Prof. Dr. Christoph Hartl
• Main focus of research activities

Manufacturingprocessesoptimisation, tools
machine systems
Microhydroformingprocess development, tools
machine systems
Laserprocessingprototype development,feasibilit
y studies
FEA-Simulationlinear and non-linear
studies,component design process feasibility
X-ray image of laser soldered component
Micro hydroforming tool system
Process simulation result
Process analysis
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• Involvement in Masmicro Project

• RTD 3 Forming tools
• RTD 4 Miniature/micro forming systems

Development of micro-hydroforming machine system
Processfundamentalsparameters,feasibility,limi
ts
Flexible toolsystemdesign,try out,optimisation
Manufacturingaccuracystrategies,tool process
design
Prototype ofseries productionmachine
design,try out optimisation
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• Hydroforming principle

• Process principle

• Typical manufacturing chain for hydroformed parts

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• Fundamentals of micro hydroforming

• Enhanced forming with laser assisted expansion

Size dependent effects
Expansion tests and results (tube material
AISI304, OD 800 µm, WT 100 µm)

• Availability of device for bursting pressure
  tests on micro tubes

Principle
Test device
Results (tube material AISI304, OD 800 µm, WT 40
µm)
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• Sealing principles and media delivery

• Optimised sealing design

Optimisation of punch design by use of
FEA(internal pressure 4000 bar)
Conventional sealing with axial feeding
Conical sealing punch

• Investigated micro flow behaviour

(Cousin R, Hartl Ch, 2006)
CFD-simulation of micro tube filling process
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• Micro hydroforming tool

• Flexibility and measuresfor reduced tool
  deflection

Micro hydroforming tool half(manufactured by
Pascoe Engineering Ltd.)
Micro hydroforming prototype component(base tube
AISI 304, OD 800µm, WT 40 µm)
Strategy for reducing tool deflectionverified by
the use of FEA
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• Micro hydroforming machine

• Machine prototypecapable of series production-
  internal pressure 4000 bar- closing force 20
  kN- closing speed 15 m/s- axial force 800 N-
  flexible control of 4 axis- designed for a cycle
  time of about 6 sec

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• Details of press design

• Optimised for accuracy

Optimisation of frame deflection by use of
FEAmax. vertical deflection 4?10-4 mm (load 20
kN)
Built up of micro hydroforming press
Guiding system independently from frame deflection
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• Summary

• Fundamentals of micro hydroforming processes have
  been developed and feasibility has been
  demonstrated
• Sealing techniques for pressurized micro tubes
  have been successfully tested for internal
  pressures up to 4000 bar
• Design principles for flexible tool systems are
  available and strategy for reduction of tool
  deflection has been developed
• A micro hydroforming prototype machine has been
  constructed which is capable of series production
• Applications are predominantly to be seen in the
  fields of medical engineering, micro fluidic and
  micro mechatronic

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• Contact

• Prof. Dr. Christoph Hartl
• Faculty 08
• Institute of Production
• Betzdorfer Str. 2
• 50679 Cologne
• Germany
• Tel. [phone]
• Fax [phone]
• E-Mail christoph.hartl_at_fh-koeln.de
• www.fh-koeln.de