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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???