Tube Hudroforming Step By Step Process

1. If the shape contains bends that deviate from a straight line, the raw tube
is loaded into the tube bender. This bends the tube giving it the necessary
curvature in order to fit into the dies.
2. The bent Tube is then typically placed in either our 200 or 500 ton preform press. These presses will initiate the forming and shape change of
the part and assist in the hydroforming process.
3. The part then goes to a hydroforming press. This press will pressurize
the water inside the tube and give the part its final shape and look. (Fig
A.)
4. Newly hydroformed parts go through a parts wash as required to
ensure precision laser cutting or stenciling.
5. Finally, the part is taken to the laser center for specific cutting, etching,
or trimming purposes.

American Hydroformers in-house tube bending equipment and capabilities

support our hydroforming operations. If a finished part contains bends that
deviate from a straight line, tube bending is often required. This, along with
the pre-crush stage of production, ensures the tube will fit properly into the
hydroforming die. Additionally the tube bending process thins the outer
radius wall and thickens the inner wall. Our team of designers and engineers
utilize FEA simulations to accurately predict the thinning and stress per
different material usage. Current bending operation allows for bending of up
to a 5 OD tube with a .100 steel wall thickness. Our electric and CNC
controlled rotary draw benders are capable of multi-stack tooling, allowing
different radius bends on the same part. These benders can use a mandrel
when required to maintain roundness and minimize thinning on the outer
diameter portion of the bend.