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