HYDRO FORMINGPresented by:Nishal JoseReg. No: 89020695
OUTLINEWhat is Hydro FormingHow and where is Hydro Forming usedMaterials used in Hydro Forming processesDesign ConsiderationsAdvantages/DisadvantagesEconomics of Hydro FormingWebsites and LinksConclusion
High Pressure Water As a Punch
Widely Used In Automobile Industry
HYDRO FORMED COMPONENTSAutomobile Component & Bellows
Handle Bar T- Junction
METHODS OF HYDROFORMING
There are two types : Tube Hydro Forming
Sheet Hydro Forming
TUBE HYDRO FORMINGUsed 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
TUBE HYDRO FORMING
BENEFITS OF TUBE HYDRO FORMINGIncreased Strength To Weight RatiosReduction In WeightReduction In Production CostReduction In Number Of Manufacturing StagesImproved Stiffness, Torsion And Bending RigidityLess Floor Area
Step 1Fig. Final Product
SHEET HYDRO FORMING2 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 FORMINGStructurally Closed Components Are Formed By This ProcessHigh Pressure Process
HYDRO FORMING PROCESS CONTROLController Plays A Virtual Role In Displaying, Monitoring And Controlling
APPLICATION SPECTRUMAutomotive Components Well Suited To Hydro Forming Of Sheets.
Outer Skin With Its 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 shell2. Driving shaft3. Assembled camshaft4. Exhaust systems5. Engine cooling system6. Radiator frame7. Safety requirements8. Engine bearer9. Integral member10. Cross member11. Frame structure parts12. Axle elements
MATERIALSSteel (mild and harder steels)
Research continues to expand the capabilities of the hydroforming process
ADVANTAGESHydroforming draws material into the moldPart consolidationWeight reduction through more efficient section design and tailoring of the wall thickness Improved structural strength and stiffnessLower tooling cost due to fewer partsFewer secondary operations (no welding of sections required and holes may be punched during hydroforming)Tight dimensional tolerances and low spring back Reduced scrap
DISADVANTAGESSlow cycle time
Expensive equipment and lack of extensive knowledge base for process and tool design.
Requires new welding techniques for assembly.
CONCLUSIONHydroforming 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 WEBwww.hydroforming.netwww.vari-form.comwww.hdt-gti.comwww.revindustries.comwww.autosteel.orgwww.schuler-hydroforming.dewww.egr.msu.edu/~aenader