HYDROFORMING

Presented by:
Byron Erath
Duane Ellsworth
 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
 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
 TUBE HYDROFORMING
 Used when a complex shape is Section A - A
Outer tool part
needed
Tube

 A section of cold-rolled steel

tubing is placed in a closed die Inner tool part
Upper tool part
not shown

set

 A pressurized fluid is
introduced into the ends of the
tube

 The tube is reshaped to the

confine of the cavity
 SHEET HYDROFORMING
2 METHODS:

 Sheet steel is forced into a female cavity by water

under pressure from a pump or by press action
 Sheet steel is deformed by a male punch, which
acts against the fluid under pressure.

Note: Sheet hydroforming provides a work-hardening effect as the steel is forced against the
blanks through fluid pressure.
 APPLICATIONS
 Automotive industry

 Sanitary use

 Aerospace
– Lighter, stiffer parts
Chevy SSR Frame
 APPLICATIONS (CONT)
1. Body shell
2. Driving shaft
3. Assembled camshaft
4. Exhaust systems
5. Engine cooling system
6. Radiator frame
7. Safety requirements
8. Engine bearer
9. Integral member
10. Cross member
11. Frame structure parts
12. Axle elements
 MATERIALS
 Steel (mild and harder steels)
 Stainless Steel
 Aluminum alloys
 Research continues to expand the
capabilities of the hydroforming process
 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
 DESIGN CONSIDERATIONS
Product Tool/Dies Equipment
- Geometry, thickness -Geometry of tools - Press capacity
distribution
- Dimensional - Material hardness - Speed/production rate
accuracy/tolerances - Surface conditions - Force/energy capabilities
- Surface finish - Stiffness and accuracy - Rigidity and accuracy
- Microstructure, mechanical
and metallurgical
properties, hardness

Work piece/Material Deformation zone

- Deformation mechanics, model used
-Flow stress as a function of strain, strain rate and for analysis
microstructure - Metal flow, velocities, strain rates,
-Workability as a function of strain, strain rate and strains (kinematics)
microstructure - Stresses (variation during
- Surface conditions deformation)
- Geometry of tubing ( outside diameter, tube wall
thickness, roundness, properties of welding line, etc.)
 ADVANTAGES
 Hydroforming draws material into the mold
 Part consolidation
 Weight reduction through more efficient
section design and tailoring of the wall
thickness
 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
 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)
 DISADVANTAGES
 Slow cycle time

 Expensive equipment and lack of extensive knowledge

base for process and tool design

 Requires new welding techniques for assembly.

ECONOMICS
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
 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!

QUESTIONS???