HYDRO FORMINGHYDRO FORMING
Presented by:
Nishal Jose
Reg. No: 89020695
OUTLINE
What is Hydro Forming How and where is Hydro Forming used Materials used in Hydro Forming processes Design Considerations Advantages/Disadvantages Economics of Hydro Forming Websites and Links Conclusion
INTRODUCTION
Hydro Forming
High Pressure Water As a Punch
Widely Used In Automobile Industry
HYDRO FORMED COMPONENTS
Automobile Component & Bellows
Handle Bar T- Junction
METHODS OF HYDROFORMING
There are two types :
Tube Hydro Forming
Sheet Hydro Forming
TUBE HYDRO FORMING Used when a complex shape
is needed
A section of cold-rolled steel tubing is placed in a closed die set
A pressurized fluid is
introduced into the ends of the tube
The tube is reshaped to the confine of the cavity
Outer tool part
Tube
Inner tool part
Section A - A
Upper tool partnot shown
TUBE HYDRO FORMING
BENEFITS OF TUBE HYDRO FORMING
Increased Strength To Weight Ratio’sReduction In WeightReduction In Production CostReduction In Number Of Manufacturing
StagesImproved Stiffness, Torsion And Bending
RigidityLess Floor Area
Step 2
Step 3
Step 1
Fig. Final Product
SHEET HYDRO FORMING
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.
SINGLE SHEET HYDRO FORMING
DOUBLE SHEET HYDRO FORMING
Structurally Closed Components Are Formed By This Process
High Pressure Process
HYDRO FORMING PROCESS CONTROL
Controller Plays A Virtual Role In Displaying, Monitoring And Controlling
APPLICATION SPECTRUM
Automotive Components Well Suited To Hydro Forming Of Sheets.
Outer Skin With It’s Extreme Demand Of Surface Quality And Dimensional Accuracy.
Longer Outer Skin Parts For Passenger Cars, Utility Vehicles And Truck Such As Goods.
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
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
DISADVANTAGES
Slow cycle time
Expensive equipment and lack of extensive knowledge base for process and tool design.
Requires new welding techniques for assembly.
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!
INFORMATION ON THE WEB
www.hydroforming.netwww.vari-form.comwww.hdt-gti.comwww.revindustries.comwww.autosteel.orgwww.schuler-hydroforming.dewww.egr.msu.edu/~aenader
QUESTIONS???
THANK YOUTHANK YOU