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    Hydroforming: Presented By: Byron Erath Duane Ellsworth

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    bathinsreenivas
    Hydroforming uses pressurized fluids to shape metal parts. There are two types: tube hydroforming forms tubing into complex shapes by forcing fluid into the ends, while sheet hydroforming shapes flat metal by pressing it into a die using fluid pressure or a punch. Hydroforming is increasingly used in automotive and aerospace applications to make parts that are lighter, stronger, and need fewer assembly steps than traditional techniques. While offering advantages like reduced weight and complexity, hydroforming also has higher costs and slower production speeds than some other forming methods.

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    Hydroforming: Presented By: Byron Erath Duane Ellsworth

    Uploaded by

    bathinsreenivas
    173 views17 pages
    Hydroforming uses pressurized fluids to shape metal parts. There are two types: tube hydroforming forms tubing into complex shapes by forcing fluid into the ends, while sheet hydroforming shapes flat metal by pressing it into a die using fluid pressure or a punch. Hydroforming is increasingly used in automotive and aerospace applications to make parts that are lighter, stronger, and need fewer assembly steps than traditional techniques. While offering advantages like reduced weight and complexity, hydroforming also has higher costs and slower production speeds than some other forming methods.

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    Hydroforming uses pressurized fluids to shape metal parts. There are two types: tube hydroforming forms tubing into complex shapes by forcing fluid into the ends, while sheet hydroforming shapes flat metal by pressing it into a die using fluid pressure or a punch. Hydroforming is increasingly used in automotive and aerospace applications to make parts that are lighter, stronger, and need fewer assembly steps than traditional techniques. While offering advantages like reduced weight and complexity, hydroforming also has higher costs and slower production speeds than some other forming methods.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    173 views17 pages

    Hydroforming: Presented By: Byron Erath Duane Ellsworth

    Uploaded by

    bathinsreenivas
    Hydroforming uses pressurized fluids to shape metal parts. There are two types: tube hydroforming forms tubing into complex shapes by forcing fluid into the ends, while sheet hydroforming shapes flat metal by pressing it into a die using fluid pressure or a punch. Hydroforming is increasingly used in automotive and aerospace applications to make parts that are lighter, stronger, and need fewer assembly steps than traditional techniques. While offering advantages like reduced weight and complexity, hydroforming also has higher costs and slower production speeds than some other forming methods.

    Copyright:

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    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 17

    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 needed


    Tube

    Outer tool part

    Section A - A

    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

    Inner tool part

    Upper tool part not shown

    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 lowpressure 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
    - Geometry, thickness distribution - Dimensional accuracy/tolerances - Surface finish - Microstructure, mechanical and metallurgical properties, hardness

    Tool/Dies
    -Geometry of tools - Material hardness - Surface conditions - Stiffness and accuracy

    Equipment
    - Press capacity - Speed/production rate - Force/energy capabilities - Rigidity and accuracy

    Work piece/Material
    -Flow stress as a function of strain, strain rate and microstructure -Workability as a function of strain, strain rate and microstructure - Surface conditions

    Deformation zone
    - Deformation mechanics, model used for analysis - Metal flow, velocities, strain rates, strains (kinematics) - Stresses (variation during 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???

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