HydroForming.ppt

7/29/2019 HydroForming.ppt

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HYDROFORMING

Presented by:

Byron Erath

Duane Ellsworth


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OUTLINE:

What is Hydroforming

How and where is Hydroforming used Materials used in Hydroforming processes

Design Considerations

Advantages/Disadvantages

Economics of Hydroforming

Websites and Links

Conclusion


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HYDROFORMING

Hydroforming uses the force of water or hydraulic

fluids to shape a single part.

There are two types of hydroforming:

1. Tube hydroforming

2. Sheet hydroforming


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TUBE HYDROFORMING

Used when a complex shape isneeded

A section of cold-rolled steeltubing is placed in a closed dieset

A pressurized fluid is

introduced into the ends of thetube

The tube is reshaped to the

confine of the cavity

Outer tool part

Tube

Inner tool part

Section A - A

Upper tool part

not shown


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SHEET HYDROFORMING

2 METHODS:

Sheet steel is forced into a female cavity by waterunder pressure from a pump or by press action

Sheet steel is deformed by a male punch, whichacts against the fluid under pressure.

Note: Sheet hydroforming provides a work-hardening effect as the steel is forced against the

blanks through fluid pressure.


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APPLICATIONS

Automotive industry

Sanitary use

Aerospace

Lighter, stiffer parts

Chevy SSR Frame


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APPLICATIONS (CONT)

1. Body shell

2. Driving shaft

3. Assembled camshaft

4. Exhaust systems5. Engine cooling system

6. Radiator frame

7. Safety requirements

8. Engine bearer

9. Integral member10. Cross member

11. Frame structure parts

12. Axle elements


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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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DESIGN CONSIDERATIONS

Hydroforming is generally defined as either low-

pressure 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


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DESIGN CONSIDERATIONSProduct

- Geometry, thickness

distribution

- Dimensional

accuracy/tolerances

- Surface finish- Microstructure, mechanical

and metallurgical

properties, hardness

Tool/Dies

-Geometry of tools

- Material hardness

- Surface conditions

- Stiffness and accuracy

Equipment

- Press capacity

- Speed/production rate

- Force/energy capabilities

- Rigidity and accuracy

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 wallthickness, roundness, properties of welding line, etc.)

Deformation zone- Deformation mechanics, model used

for analysis

- Metal flow, velocities, strain rates,

strains (kinematics)

- Stresses (variation during

deformation)


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ADVANTAGES

Hydroforming draws material into the mold

Part consolidation

Weight reduction through more efficient

section design and tailoring of the wallthickness

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


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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 knowledgebase for process and tool design

Requires new welding techniques for assembly.


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ECONOMICS


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INFORMATION ON THE WEB

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


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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 toincrease

Information can be found everywhere!


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QUESTIONS???

HydroForming.ppt

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